An Industrial Oriented Mini Project Report on

ANALYSIS OF THERMAL POWEWR PLANT COMPONENTS AND ELECTRICAL

PROTECTION IN KTPP

Submitted in partial fulfilment for award of the degree of Bachelor of Technology

In

Electrical and Electronics Engineering Department

by
J. Nandini 23321A0217
L. Navya Sri 23321A0219
M. Nandini 23321A0218

Under the esteemed Guidance of

Mrs. J. Ashwini Kumari , MTech(EPS)
Assistant Professor, EEE Department

Bhoj Reddy Engineering College for Women

Department of Electrical and Electronics Engineering
(Sponsored by Sangam Laxmibai Vidyapeet, Accredited by NAAC with A Grade, Approved by AICTE and Affiliated to
JNTUH, Recognized by UGC under section 2(f) of the UGC Act, 1956)
Vinaynagar, IS Sadan Crossroads, Hyderabad – 500 059
Ph: +91-40-2453 7282; Website: [Link]; Email: principal@[Link]
2023 – 2027
 Bhoj Reddy Engineering College for Women
(Sponsored by Sangam Laxmibai Vidyapeet, Accredited by NAAC with A Grade, Approved by
AICTE and Affiliated to JNTUH, Recognized by UGC under section 2(f) of the UGC Act, 1956)
Vinaynagar, I S Sadan Crossroads, Hyderabad 500 059, Telangana
Telephone: 040-2453 7282, Website: [Link], Email: principal@[Link]

Date:
CERTIFICATE

This is to certify that the Industrial oriented mini project Report entitled
“ANALYSIS OF THERMAL POWER PLANT COMPONENTS AND
ELECTRICAL PROTECTION IN KTPP” is a Bonafide work carried out by

J. Nandini 23321A0217
L. Navya Sri 23321A0219
M. Nandini 23321A0218

in partial fulfillment for award of the degree of Bachelor of Technology in

Electrical and Electronics Engineering department from Bhoj Reddy Engineering
College for Women, Hyderabad, affiliated to Jawaharlal Nehru Technological
University Hyderabad (JNTUH).

Internal Guide Head of the Department

J. Ashwini kumari, MTech(EPS) Dr. S. Asha Kiranmai, Ph.D.
(OU)
Assistant professor, EEE Associate Professor, HOD-EEE

External Examiner
Sangam Laxmibai Vidyapeet is an educational society for promotion of education among girls
and women.
It is established in 1952 and registered under the Telangana Societies Registration Act.
 DECLARATION

We hereby declare that the work presented in this project entitled “ANALYSIS OF
THERMAL POWER PLANT COMPONENTS AND ELECTRICAL
PROTECTION IN KTPP” submitted towards completion of Industrial Oriented
Mini Project in III year of [Link]. EEE at ‘Bhoj Reddy Engineering College for
Women’, Hyderabad, is an authentic record of our original work carried out under
the guidance of Mrs. J. Ashwini Kumari, [Link](EPS),Assistant professor

Sign. with date:

J. Nandini(23321A0217)

Sign. with date:

L. Navya Sri (23321A0219)

Sign. with date:

M. Nandini(23321A0218)
 ACKNOWLEDGEMENTS

The satisfaction and euphoria that accompanies the completion of task would be incomplete
without the mention of the people whose constant guidance and encouragement have crowned
our efforts in success.
It gives us an immense pleasure to express deep gratitude and respect to our internal guide,
Mrs. J. Ashwini Kumari, [Link](EPS), Assistant Professor, Department of EEE, BRECW,
for the eminent guidance and suggestions she has provided for successful completion of the
Industrial Oriented Mini Project.
We are grateful to our external guide, Mr. M. Santhosh ADE TSGENCO KTPP-II Stage
Chelpur, for his valuable guidance, motivation, suggestions and providing us with necessary
facilities, which enable us to complete the project successfully.

We thank Dr. S. Asha Kiranmai, M.E., Ph.D.(OU) Head of the Department, EEE, BRECW,
for giving timely cooperation and taking necessary action throughout the course of our project.

We also thank Dr. G. Shyama Chandra prasad Principal, BRECW, for providing us an
opportunity to carry out the project.
Last but not the least; we would like to acknowledge all those, whose names cannot be penned
here, but who were directly or indirectly are a part of this project.

J. Nandini (23321A0217)
L. Navya Sri (23321A0219)
M. Nandini (23321A0218)
 CONTENTS

DESCRIPTION PAGE
NO.

LIST OF FIGURES................................................................................i

LIST OF TABLES................................................................................ii

ABSTRACT........................................................................................iii

1. INTRODUCTION............................................................................... 1

1.1 Literature Survey........................................................................................5

1.2 Objective.....................................................................................................5

1.3 Organization of the Report..........................................................................6

2. OVERVIEW OF KTPP........................................................................... 8

2.1 Components of thermal power plant...........................................................8

2.1.1 Boiler.....................................................................................................9

2.1.2 Heater...................................................................................................10

2.1.3 HP Turbine...........................................................................................11

2.1.4 IP Turbine .............................................................................................12

2.1.5 LP Turbine ............................................................................................13

2.2 Generator...................................................................................................14

2.3 Condenser.................................................................................................15

2.4 Cooling Tower..........................................................................................16

3. HIGH TENSION MOTORS OPERATED AT HIGH VOLTAGES...................17

 3.1 Definition..................................................................................................17

3.2 Working principle of Induction/HT Motor...............................................18

3.3 Types Of Induction Motor........................................................................18

3.3.1 Single Phase Induction Motor.............................................................18

3.3.2 Three Phase Induction Motor.............................................................19

3.4 Stator Of Three Phase Motor....................................................................19

4. TYPES OF HT MOTORS USED IN KTPP............................................................20

4.1 Circulating Water Pump Motor.................................................................20

4.2 Condensate Extraction Pumps Motor.......................................................21

4.3 M.D.B.F.P.................................................................................................21

4.4 Coal Mill Motor.......................................................................................22

4.5 P.A Fan Motor..........................................................................................23

4.6 F.D Fan.....................................................................................................24

4.7 I.D Fan.....................................................................................................29

4.8 H.P Fan.....................................................................................................26

4.9 A.C.W.P Motor.........................................................................................26

4.10 TAC Motor..............................................................................................26

4.11 DMCW-TG Motor .................................................................................26

4.12 DMCW-SG Motor..................................................................................26

4.13 IAC/SAC Motor......................................................................................26

4.14 B.C.W Motor...........................................................................................26

4.15HP Motors above 200KW........................................................................26

5. MOTOR MAINTENANCE.....................................................................................20

5.1 Objective...................................................................................................35
 5.2 Periodic Inspections.................................................................................35

6. SWITCH GEAR..........................................................................................................20

6.1 Definition Of Switch Gear........................................................................35

6.2 Parts Of Switch Gear...............................................................................35

7. HT SWTICHYARD....................................................................................................20

7.1 Types of feeders .......................................................................................35

8. MAINTENANCE OF SWITCHGEAR....................................................................20

8.1 Need of maintenance.................................................................................35

8.2 Elements of effective maintain program...................................................35

8.3 Slow closing and opening operation ........................................................35

8.4 Inspection of vacuum level.......................................................................35

Block Diagram................................................................................................32

1.1 Power flow................................................................................................34

 ABSTRACT
This project deals with power generation, transmission and efficiency in Kakatiya thermal
power plant. Kakatiya thermal power plant has a total capacity of 1,100MW consisting of two
units i.e., unit 1 and unit 2. Unit 1 has a capacity of 500MW and unit 2 has a capacity of
600MW. The plant load factor is 85.36%. KTPP utilizes around 16,000 tons of coal daily for its
operation. The primary objective of this study is to understand the complete power generation
process starting from coal handling, boiler operation, steam generation, turbine rotation, and
conversion of mechanical energy into electrical energy using synchronous generators. The
installed capacity and unit rating of KTPP units are analyzed to determine the total power output
and operational performance of the plant. Preventative and predictive maintenance programs for
motors are effective practices in manufacturing plants. These maintenance procedures involve a
sequence of steps plant personnel use to prolong motor life or foresee a motor failure. The
technicians use a series of diagnostics such as motors temperature and motor vibrations as key
pieces of information in learning about the goal of predictive maintenance programs is to reduce
maintenance costs by detecting problems easily which allow for better maintenance planning
and less unexpected failures. Predictive maintenance programs for motors observe the
temperature. Overall, this project provides a clear and practical understanding of large-scale
thermal power generation and transmission systems in Kakatiya Thermal Power Plant
 [Link] TO KTPP-BHUPALPALLY
1.1 INTRODUCTION

The Kakatiya Thermal Power Project Telangana Generation Corporation Limited is situated at
Chelpur village of Ghanpur mandal in the Bhupalpally district. It is connected to Warangal by
road at a distance of 60 kms and 220 kms from Hyderabad. Kakatiya Thermal Power Project
consists of 1X500 MW Stage-I and 1X600 MW-Stage-II. Stage-I commissioned and COD
declared on 14.09.2010. Stage-II commissioned and COD declared on 24.03.2016. The fuel
(Coal) is supplying by SCCL from the Mines of Bhupalpally and Godavarikhani. Water is lifting
from the river Godavari by underground pipe line from Kaleshwaram which is 60 kms.
Kakatiya Thermal Power Project is a green filled project and is a pit head station. The first stage
was synchronized with grid first time on 31.03.2010.
The Power Generated from Kakatiya Thermal Power Project is evacuated by 2x400KV lines
and connected to Power Grid Corporation of India Ltd substation at Chandrapur.

Location Chelpur (V), Ghanpur (M), Bhupalpally (Dist.), Telangana

Latitude 18026’ 54” N

Longitude 79045’ 32” E

Nearest SH-7 Connecting Parkal with Mahadevpur

Highway
Major Crops Rice during rainy season, cash crops such as maize,
groundnut, cotton etc. in other seasons.

Nearest City Warangal (60 km) SW

Nearest Uppal Railway Station of South-Central Railway Located at

Railway about 40 km from plant site.
Station
Nearest Air Hyderabad, 220 km
Port
Table1.1 - Salient Features of KTPP

The basic principle involved is Faraday’s law of electro-magnetic induction i.e. “whenever a
conductor cuts a magnetic flux emf is induced across its ends”. The basic physics involved in
this is the internal energy and enthalpy of the steam gets converted to the very first thing we
need to provide is a conductor cutting magnetic flux. So, this can be done in two basic ways i.e.
either the conductor can be moved in the magnetic field or the field can be varied according to
the required emf that is to be generated. The process we follow here is we rotate the rotor of a
generator in the magnetic field and emf is generator at the stator and this generated emf is
1
further utilized according to the purpose. To meet the purpose of rotating the rotor of a
generator, the rotating shaft is in turn connected to a turbine which is made to rotate at a rated
speed by an external energy source. So, we need an energy source to rotate the turbine. To rotate
the turbine energy must be transferred from a medium to the turbine so that energy from the
external source is converted to rotational energy of turbine. In general, to rotate an object which
is mounted we need to apply some torque. To produce torque, we need to apply force in the
tangential direction. For the purpose of application of force, we chose steam

SUPERIORITY OF ELECTRICAL ENERGY

Electrical energy is considered the most superior form of energy because it is easy to generate,
transmit, distribute, and convert into other useful forms of energy. In thermal power plants like
the Kakatiya Thermal Power Plant at Chelpur, coal is burned to produce heat energy, which
converts water into steam. The steam rotates a turbine, and the turbine drives an alternator to
produce electrical energy that is supplied to consumers.
Another reason for the superiority of electrical energy is its versatility. Electrical energy can
easily be converted into other forms such as mechanical energy (in motors), heat energy (in
heaters), light energy (in lamps), and sound energy (in speakers). Because of this flexibility,
electricity is widely used in homes, industries, transportation systems, and communication
networks
THERMAL POWER PLANT

Fig 1.1 Thermal power plant

A thermal power plant is a generating station where heat energy is converted into electrical

energy. In this plant, fuel such as coal is burned in a boiler to produce heat. The heat converts

water into high-pressure steam. This steam is then passed to a turbine, where it strikes the

2
turbine blades and makes the turbine rotate. The turbine shaft is connected to a generator, and

when it rotates, electrical energy is produced.

After passing through the turbine, the steam enters a condenser where it is cooled and converted
back into water. This water is again pumped to the boiler to repeat the cycle. The electricity
generated in the generator is sent to the switchyard, where the voltage is increased and
transmitted through transmission lines to different places. Thermal power plants are widely used
because they can produce a large amount of electricity continuously to meet the power demand
of industries, homes, and commercial areas. In the same way we need to send the steam with a
greater force in turn with a greater pressure to make the turbine rotate mechanical energy that
rotates the turbine.
Our target is to produce steam at a very high pressure. Pressure of the steam can be increased by
various auxiliaries through different mechanisms. So basically, we need to produce steam. For
the production of steam water is to be heated to high temperatures with the help of available
fuel.
Combustion of fuel is done and evolved heat is utilized for production of steam. Total idea is to
be implemented in a highly efficient way to balance the finance and economy. Environmental
protection should also be the point of concern because burning of fuel may evolve gases which
are responsible for harmful effects that distract our ambience.
ABOUT KTPP I AND II STAGES:

Kakatiya thermal power plant has a total capacity of 1,100MW consisting of two units i.e., unit

1 and unit 2. Unit 1 has a capacity of 500MW and unit 2 has a capacity of 600MW. The plant

load factor is 85.36%. KTPP utilizes around 16,000 tons of coal daily for its operation.

Installed Capacity:

Thus the total installed capacity of the plant is :

KTPS – unit 1:500mw(commissioned in the year 2010)

KTPS – unit 2: 600mw(commissioned in the year 2016)

TOTAL = 1100MW

Vision:

To be the best power utility in the country and one of the best in the world.
Mission:
To generate adequate and reliable power most economically, efficiently and eco-friendly.
3
 To spearhead accelerated power development by planning and implementing new power
projects.
To implement renovation and modernization of all existing units and enhance their
performance.
KAKATHIYA THERMAL POWER STATION CONSISTS OF 2 UNITS IN TOTAL AS
FOLLOWS:
Date
Stage Unit Installed of status
Number Capacity(MW) Commissioning

Stage I 1 500 31-03-2010 runnin

g

Stage I 2 600 22-10-2016 runnin

g
Table 1.2 plant units

LITERATURE SURVEY

Mudita Dubey and Abhay Sharma conducted a research study on improving the efficiency of
thermal power plant equipment through a thermal audit of a 210 MW coal-based thermal power
plant. The study focuses on analysing the energy performance of different components of the
plant using operational data. The plant cycle was divided into three major sections for analysis:
the main steam system, the turbine-condenser-feed pump system, and the complete plant system
including the boiler, turbo-generator, regenerative heaters, and auxiliary equipment
The research aims to identify energy losses occurring in different parts of the thermal power
plant and evaluate their effect on overall plant efficiency. The analysis shows that parameters
such as condenser pressure, load conditions, and regenerative heater operation significantly
affect the plant efficiency. The study also explains that maintaining proper steam pressure and
optimizing turbine governing systems can improve plant performance during part-load
operation. The results of the thermal audit help engineers identify areas where efficiency
improvements can be made in thermal power plants

Rupam et al. analyzed the technical efficiency of a thermal power plant by evaluating
operational parameters and energy utilization. The research examines the performance of major
components such as boilers, turbines, and generators to determine their contribution to overall
4
plant efficiency. The study highlights the importance of monitoring operating conditions and
improving system performance to achieve better energy conversion efficiency in thermal power
plants.
Rangaswamy et al. presented a study on protection and interlock systems used in thermal power
plants to safeguard critical equipment such as boilers, turbines, and generators. The research
explains the importance of protective relays and interlocking mechanisms in preventing
equipment damage during abnormal operating conditions. The study also highlights how
effective protection systems help reduce unwanted plant trips, maintenance costs, and
generation losses while improving overall plant reliability and safety.
Objectives:
One of the important objectives of K.T.P.P. is to generate thermal power efficiently and
economically. It is also fulfilling the role of social responsibility objective by encouraging local
small-scale industries, providing employment to the people of the backward and tribal areas. It
has crores of rupees controlling pollution by installing Electrostatic Precipitators (ESP).

1.3 ORGANISATION OF THE REPORT

Chapter 1: Presents Introduction overview a brief introduction and the objective of the
Project And Over View of KTPP are Discussed
Chapter 2: Components of Thermal Power Plant
Chapter 3: Presents the mechanism of Generator and explains how it works.
Chapter 4: Types of HT motors in KTPP and their specifications, Appications.
Chapter 5: Motor maintenance, its inspection.
Chapter 6: Switch gear operation and its working.
Chapter7: HT Switchyard and its types of feeders
Chapter 8: Need of Maintenance of Practice , operation and efficiency.
Chapter 9: Presents the conclusion and future Scope.

5
 2 OVERVIEW OF KTPP

Fig 1.2 Unit overview

BASIC IDEA OF OPERATION:

The basic principle involved is Faraday’s law of electro-magnetic induction i.e. “whenever a
conductor cuts a magnetic flux emf is induced across its ends”.
 The basic physics involved in this is the internal energy and enthalpy of the steam gets
converted to the very first thing we need to provide is a conductor cutting magnetic flux. So,
this can be done in two basic ways i.e. either the conductor can be moved in the magnetic
field or the field can be varied according to the required emf that is to be generated. The
process we follow here is we rotate the rotor of a generator in the magnetic field and emf is
generator at the stator and this generated emf is further utilized according to the purpose.
 To meet the purpose of rotating the rotor of a generator, the rotating shaft is in turn
connected to a turbine which is made to rotate at a rated speed by an external energy source.
So, we need an energy source to rotate the turbine..

6
Steam Flow
Boiler → Drum → Super Heater → HP Turbine → Re Heater → IP Turbine → LP Turbine →
Condenser
Feed Water Flow
Condenser → CEP’s → LPH → Deaerator → BFP’s → HP Heaters → Economizer → Drum
→ Boiler

2.1 COMPONENTS OF THERMAL POWER PLANT

A thermal power plant primarily consists of several key components that work together to
convert heat energy into electrical energy. The core element is the boiler, where fuel commonly
coal is burned to produce steam. This steam is generated at high pressure and temperature and is
directed to a turbine. The turbine, equipped with blades, converts the steam's thermal energy
into mechanical energy as it spins. Connected to the turbine is a generator that transforms this
mechanical energy into electrical energy. After passing through the turbine, the steam enters a
condenser, where it is cooled and converted back into water, making it reusable in the boiler.
Additionally, thermal power plants have auxiliary systems, including feedwater pumps, cooling
towers, and emission control devices to manage pollutants and enhance efficiency. These
components work cohesively to ensure the continuous and effective generation of electricity.
2.1.1Boiler:
The boiler used in Kakatiya Thermal Power Plant (KTPP) Stage-2 is a coal-fired water tube
boiler designed and manufactured by Bharat Heavy Electricals Limited (BHEL). The plant has a
600 MW generating unit, and the boiler is designed to produce a large amount of high-pressure
and high-temperature steam required to drive the turbine. In a water tube boiler, water flows
inside tubes while hot flue gases produced from coal combustion flow outside the tubes. This
design allows the boiler to withstand very high operating conditions. In KTPP Stage-2, the
boiler generates steam at a temperature of around 540°C to 545°C and a pressure of
approximately 170 bar, which is suitable for efficient power generation.
The boiler works on the pulverized coal combustion principle. Coal from the coal handling plant
is first crushed and then ground into a fine powder in coal mills. The powdered coal is mixed
with preheated air and blown into the furnace where it burns at a very high temperature. The
heat produced in the furnace is absorbed by water circulating through the boiler tubes known as
water walls. As the water absorbs heat, it converts into steam and collects in the boiler drum.
The steam then flows through the superheater, where its temperature is increased to about
540°C, producing superheated steam before entering the high-pressure turbine.
The boiler system in KTPP includes several major components such as the furnace, boiler drum,
water walls, superheater, reheater, economizer, and air preheater. The economizer increases the
7
temperature of the feed water before it enters the boiler drum, improving overall efficiency. The
air preheater heats the air used for coal combustion, which helps achieve better fuel burning and
energy utilization. After passing through the high-pressure turbine, the steam returns to the
reheater, where its temperature is again increased to around 540°C before entering the
intermediate-pressure turbine.

Fig 2.1.1Boiler

2.1.2 Heater:
The superheater is a crucial component of the boiler system, responsible for increasing the
temperature of steam well above its saturation point. After water is converted into saturated
steam in the boiler drum and water walls, it is passed through the superheater sections where
additional heat from flue gases raises its temperature to around 540°C (as indicated in your
diagram). This process produces dry, high-temperature steam, which is essential for efficient
turbine operation and to prevent moisture-related damage to turbine blades.
The superheater used in KTPP is typically a multi-stage superheater system, consisting of
primary (low-temperature) superheater and final (high-temperature) superheater sections. These
are arranged in different temperature zones within the boiler flue gas path. The primary
superheater is placed in a relatively cooler region and starts the heating process, while the final
superheater is located in the hottest zone of the furnace or convection path, where it raises the
steam to the desired final temperature. This staged arrangement ensures controlled heating and
avoids thermal stress on the tubes.

8
 Fig 2.1.2 Super Heater in boiler
To maintain a constant steam temperature despite load variations, KTPP uses temperature
control systems such as attemperators (desuperheaters). These devices spray a controlled
amount of water into the steam between superheater stages to reduce its temperature when it
exceeds the desired limit. This is important because excessively high temperatures can damage
turbine components, while lower temperatures reduce efficiency.
Overall, the superheater in KTPP plays a vital role in improving the thermal efficiency of the
plant. By supplying high-temperature, dry steam to the turbine, it ensures maximum energy
extraction, reduces fuel consumption, and increases the life of turbine blades by preventing
condensation. It is one of the key components that enables the plant to operate at high efficiency
and reliability under varying load conditions.
2.1.3 HP Turbine:
The High Pressure (HP) turbine is the first stage of the steam turbine system and plays a critical
role in power generation. Superheated steam coming from the boiler, typically at very high
pressure and temperature (around 540°C and high pressure >100 bar), enters the HP turbine
through control valves. These valves regulate the flow of steam depending on the load demand
of the unit. The HP turbine is designed to handle this high-energy steam and convert a large
portion of its thermal energy into mechanical energy.
Inside the HP turbine, steam expands through a series of nozzles and moving blades. The
nozzles convert pressure energy into high-velocity steam jets, which strike the turbine blades
and cause the rotor to rotate. As the steam passes through successive stages, its pressure and
temperature gradually decrease while transferring energy to the turbine shaft. This rotating shaft
is directly coupled with the generator, so the mechanical energy produced in the HP turbine
contributes to electricity generation. The expansion process in the turbine ideally follows an
isentropic (constant entropy) process, although some losses occur in real operation
9
 Fig 2.1.3 HP Turbine
Overall, the HP turbine is the starting point of energy conversion in the turbine section. It
extracts the maximum possible energy from high-pressure steam and sets the stage for further
energy extraction in IP and LP turbines. Its efficient operation is essential for achieving high
output (like ~600 MW in Stage-2) and maintaining the reliability of the entire power plant.
2.1.4 IP Turbine:
The Intermediate Pressure (IP) turbine is the second stage of the steam turbine system in a
thermal power plant. It operates between the High Pressure (HP) turbine and the Low Pressure
(LP) turbine, and its main function is to extract additional energy from steam after it has already
passed through the HP turbine.
After leaving the HP turbine, the steam loses some of its pressure and temperature, but it is still
energetic. Instead of sending it directly to the IP turbine, it is first sent back to the boiler
reheater, where it is heated again to a high temperature (close to 540°C). This reheated steam is
then directed into the IP turbine. The reheating process improves efficiency and reduces
moisture formation in later stages of the turbine.
Inside the IP turbine, the steam expands through a series of blades, similar to the HP turbine. As
the steam passes over these blades, it transfers its energy to the turbine rotor, causing it to rotate.
This rotation continues to drive the same shaft connected to the generator, contributing further
to electricity generation. Compared to the HP turbine, the IP turbine operates at moderate
pressure and temperature, but still plays a major role in energy conversion. The IP turbine acts
as a middle energy extraction stage. It takes reheated steam from the boiler, extracts more
energy from it, and passes it to the LP turbine, helping to maximize the overall efficiency of the
power plant

10
 Fig 2.1.4 IP Turbine
2.1.5 LP Turbine:
The Low Pressure (LP) turbine is the final stage of the steam turbine system in the Kakatiya
Thermal Power Plant (KTPP Stage-2). It plays an important role in extracting the remaining
energy from steam after it has passed through the HP (High Pressure) and IP (Intermediate
Pressure) turbines.
After leaving the IP turbine, the steam has already lost much of its pressure and temperature, but
it still contains usable energy. This steam enters the LP turbine, where it expands further to a
very low pressure. Because the pressure is low, the volume of steam becomes very large, so the
LP turbine is physically much larger in size compared to the HP and IP turbines. It usually
consists of long blades designed to handle high steam volume and extract the remaining energy
efficiently. Inside the LP turbine, the steam flows through multiple stages of blades. As it
expands, it causes the turbine rotor to rotate, continuing to drive the same shaft connected to the
generator. Even though the energy per unit of steam is

Fig 2.1.5 LP Turbine

At the exit of the LP turbine, the steam pressure drops to a very low value (creating a vacuum),
and the steam is directed into the condenser. In the condenser, the steam is cooled using
11
circulating water and converted back into water (condensate). Maintaining this low pressure at
the LP turbine outlet improves efficiency by allowing maximum expansion of steam.
Overall, the LP turbine is essential for maximizing energy extraction from steam and improving
the overall efficiency of the plant. It ensures that almost all the usable energy from the steam is
converted into mechanical energy before the steam is condensed and reused in the cycle.
2.2 GENERATOR:
The generator used is a large synchronous turbo generator designed to produce about 600 MW
of electrical power. It is directly coupled to the steam turbine shaft, meaning the HP, IP, and LP
turbines all rotate a single shaft that drives the generator at a constant speed of 3000 RPM (for
50 Hz frequency in India).
This generator works on the principle of electromagnetic induction. The rotating part, called the
rotor, is supplied with DC excitation current, which creates a strong magnetic field. As the rotor
spins at high speed, this magnetic field rotates inside the stator, which is the stationary outer part
containing three-phase windings. This movement of the magnetic field induces an alternating
current (AC) in the stator windings, and this is the electricity that is sent to the power grid.

Fig 2.2 Generator at KTPP

The generator used in KTPP Stage-2 is typically a hydrogen-cooled generator, which is
common for high-capacity units. Hydrogen gas is used for cooling because it has excellent heat
transfer properties and low density, which reduces windage losses. In addition to hydrogen
cooling for the rotor and stator, water cooling is often used for stator windings to remove heat
effectively and maintain safe operating temperatures.
The generator operates at a voltage of around 15–21 kV, and this voltage is stepped up using a
generator transformer before being transmitted over long distances. It also includes important
auxiliary systems such as the excitation system (to supply DC current to the rotor), cooling
12
2.3 CONDENSER:
The condenser is a vital component located after the Low Pressure (LP) turbine. Its main
function is to convert the exhaust steam coming from the turbine back into water (condensate).
This is done by cooling the steam using a continuous flow of cooling water. The condenser
helps maintain a low pressure (vacuum) at the turbine outlet, which improves the efficiency of
the turbine and allows maximum extraction of energy from the steam.
The condenser used in KTPP is typically a surface condenser. In this type, the steam and
cooling water do not mix. Instead, cooling water flows inside thousands of tubes, while exhaust
steam surrounds these tubes. Heat from the steam is transferred to the cooling water through the
tube walls, causing the steam to condense into water. This design ensures that the condensate
remains pure and can be reused in the boiler cycle without contamination.
To maintain effective condensation, a large quantity of cooling water is circulated through the
condenser using circulating water pumps (CW pumps). This water usually comes from a
cooling tower or nearby water source. As the steam condenses, a vacuum is created inside the
condenser, and this vacuum is maintained with the help of air extraction systems such as
ejectors or vacuum pumps, which remove air and non-condensable gases.

Fig 2.3. Power Plant Condenser

The condensed water collected at the bottom of the condenser is called condensate, and it is
pumped by the condensate extraction pump (CEP) to the feedwater system. From there, it
passes through heaters and the deaerator before being sent back to the boiler, completing the
cycle.
Overall, the condenser plays a crucial role in improving plant efficiency, conserving water, and
maintaining continuous operation. By converting steam back into water and maintaining
vacuum conditions, it ensures that the entire steam cycle runs smoothly and efficiently.
2.4 Cooling Towers:
Cooling towers are an essential part of the cooling water system. Their main function is to
remove heat from the hot water coming out of the condenser and make it suitable for reuse.

13
After steam is condensed in the condenser, the cooling water absorbs a large amount of heat,
and this hot water is sent to the cooling tower to be cooled before being circulated back again.
Cooling towers in KTPP are typically natural draft cooling towers, which are very large
hyperbolic (curved) structures. These towers work on the principle of evaporative cooling. Hot
water from the condenser is sprayed at the top of the tower through nozzles, forming small
droplets. At the same time, air enters from the bottom of the tower and moves upward due to
natural draft (caused by temperature difference). As the air comes in contact with the falling
water droplets, a small portion of water evaporates, taking away heat and thereby cooling the
remaining water.

Fig 2.4. Cooling towers at KTPP

Inside the cooling tower, there are components such as fill material, which increases the contact
surface area between air and water, improving heat transfer efficiency. There are also drift
eliminators that prevent water droplets from escaping with the outgoing air, reducing water loss.
The cooled water collects at the bottom basin of the tower and is then pumped back to the
condenser using circulating water pumps.
The cooling tower helps maintain the required low temperature of cooling water, which is very
important for efficient condensation of steam in the condenser. If the cooling water is not
sufficiently cooled, the condenser efficiency decreases, which directly affects the overall
efficiency of the power plant.

[Link] TENSION MOTORS OPERATED AT HIGH VOLTAGES

14
3.1 Definition:
Motors supplied by high voltage above 3.3 KV are known as high tension motors.
HT is applicable for bulk purchasers of electricity like industries (big manufacturing units), big
offices, Universities, hostels and even residential colonies (if the apartment complexes purchase
together in bulk). The tariff structures of most state distribution companies are different for LT
and HT.
3.2 WORKING PRINCIPLE OF INDUCTION MOTOR (HT MOTOR):
In an induction motor, only one AC supply is given to the stator winding. When current flows
through the stator, it produces a magnetic flux. This flux rotates and cuts the rotor conductors.
Since the rotor winding is short-circuited, according to Faraday’s Law of Electromagnetic
Induction, an electric current is induced in the rotor. This induced current produces its own
magnetic flux in the rotor. Now, there are two fluxes present: the stator flux and the rotor flux,
with the rotor flux lagging behind the stator flux. Due to the interaction between these two
fluxes, a torque is produced, causing the rotor to rotate in the direction of the rotating magnetic
field. The speed of the rotor depends on the AC supply frequency and can be controlled by
varying the input supply.
3.3 TYPES OF INDUCTION MOTORS
3.3.1 SINGLE PHASE INDUCTION MOTOR:
 Split phase induction motor
 Capacitor start induction motor
 Capacitor start capacitor run induction motor
 Shaded pole induction motor
3.3.2 THREE PHASE INDUCTION MOTOR: -
• Squirrel cage induction motor
• Slip ring induction motor
We had mentioned above that single phase induction motor is not a self-starting and three phase
induction motor is self-starting. So, what is self-starting? when the machine starts running
automatically without any external force to the machine, then it is called as self-starting. For
example, we can see that when we press the key the fan starts to rotate automatically, so it is
self-starting. Point to be noted that fan used in home appliances is single phase induction motor
but it is self-starting. How? We will discuss it how.

4. TYPES OF HT MOTORS USED AT KTTP

15
 4.1. CIRCULATING WATER (C.W.) PUMP MOTORS: -
a) Specifications: -
KW 2250
DUTY CONTINUOUS
AMBIENT 50*
TEMP.
RATED 1483 RPM
SPEED
RATED 11000 VOLTS
VOLTAGE
FREQUENCY 50 HZ
RATED 154 AMPS
CURRENT
MAKE C.G. L
POWER 0.84
FACTOR
EFFICIENCY 94.5%
CONNECTIO STAR
N

FUNCTION: CW Pump is used to circulate cooling water to the Condenser; so that high pressure left out
steam in the L.P turbine can be converted into wat

16
 FIG 4.1 CIRCULATING WATER PUMP MOTOR & NAME PLATE

4.2. CONDENSATE EXTRAXTION PUMPS (C.E.P.) MOTOR

a) Specifications: -
KW 900
DUTY CONTINUOUS
AMBIENT 50*
TEMP.
RATED 1489 RPM
SPEED
RATED 3300 VOLTS
VOLTAGE
FREQUENCY 50 HZ
RATED 195 AMPS
CURRENT
MAKE BHEL
POWER 0.85
FACTOR
EFFICIENCY 95%
CONNECTION STAR
TABLE 4.2. SPECIFICATION OF C.E.P. MOTOR

17
b) FUNCTION: CEP Pump is used to extract the condensate water from the hot well an supply
to the Deaerator after passing through L.P heater and economizer, so that high pressure steam is
there in cylinder

[Link]
P MOTOR

4.3 MOTOR DRIVEN BOILER FEED PUMP(M.D.B.F.P.) MOTOR: -

No. of motor used = 3(6A, 6B, 6C)
a) Specification: -
KW 12000
DUTY CONTI
NUOU
S
AMBIE 50*
NT
TEMP.
RATED 1495
SPEED RPM
RATED 11000
VOLTA VOLTS
GE
FREQU 50 HZ
ENCY
RATED 720
CURR AMPS

18
 ENT
MAKE BHEL
POWE 0.9
R
FACTO
R
EFFICI 97.3%
ENCY
CONN STAR
ECTIO
N
TABLE 4.3 SPECIFICATION OF M.D.B.F.P MOTOR
b) FUNCTION: Its Function is to supply the water to water to the Boiler Drum. It takes
the water from the Delineator by creating a strong suction

FIG4.3
BOILER
FEEDER
PUMP MOTOR
4.4. COAL MILL MOTOR: -
No. of motor used = 3(6A, 6B, 6C)
a) Specification: -
KW 680
DUTY CONTINUOUS
AMBIENT 50*
TEMP.

19
 RATED 989 RPM
SPEED
RATED 3300 VOLTS
VOLTAGE
FREQUENCY 50 HZ
RATED 163 AMPS
CURRENT
MAKE BHEL
POWER 0.84
FACTOR
EFFICIENCY 93%
CONNECTION STAR
TABLE4.4 SPECIFICATION OF COAL MILL MOTOR

b) FUNCTION: -The Function of coal mill is to grind the coal pieces of the fine powder
(pulverized form) i.e., up to size of 25 micron.

FIG 4.4 COAL MILL MOTOR

4.5. PRIMARY AIR FAN (P.A. FAN) MOTOR: -

No. of motor used = 3(8A, 8B, 8C)
a) Specifications: -
KW 3525
DUT CON

20
Y TINU
OUS
AMB 50*
IENT
TEM
P.
RATE 1495
D RPM
SPEE
D
RATE 11000
D VOL
VOL TS
TAG
E
FRE 50
QUE HZ
NCY
RATE 213
D AMP
CUR S
REN
T
MAK BHE
E L
POW 0.85
ER
FACT
OR
EFFI 96%
CIEN
CY
CON STAR
NEC

21
 TION
TABLE 4.5 SPECIFICATION OF P.A FAN MOTOR

a) FUNCTION: Its Function is to function is to carry pulverized coal from coal mill to the
furnace for its ignition. It creates a strop it creates a strong draft of air that carries the
powdered coal

FI
G.4.5.1PRIMARY AIR FAN MOTOR

4.6. FORCE DRAUGHT (F.D.) FAN MOTOR: -

a) SPECIFICATION: -

KW 1225
DUTY CONTINUOUS
AMBIENT 50*
TEMP.
RATED 994 RPM
SPEED
RATED 3300 VOLTS
VOLTAGE
FREQUENCY 50 HZ
RATED 264 AMPS
CURRENT
MAKE BHEL
POWER 0.84
FACTOR
EFFICIENCY 94.5%
22
 CONNECTION STAR
TABLE 4.6 SPECIFICATION OF F.D FAN

b) FUNCTION: -Its function is to supply fresh air to the furnace for the proper ignition of coal
inside the furnace

FIG.4.6. FORCED DRAUGHT FAN MOTOR &NAME PLATE

4.7. INDUCED DRAFT (I.D.) FAN MOTOR: -

a) SPECIFICATION: -
KW 3725
DUTY (2WRKING,1STANDBY)
CONTINUOUS
AMBIENT 50*
TEMP.
RATED 533 RPM
SPEED
RATED 4000 VOLTS (L-L)

23
 VOLTAGE
FREQUENC 44.82 HZ
Y
RATED 329 AMPS
CURRENT
MAKE C.G. L
POWER 0.85
FACTOR
EFFICIENCY 96%
TABLE 4.7 SPECIFICATION OF I.D FAN

b) FUNCTION: Its Function is to discharge the flue gases to the Atmosphere through the
Chimney after passing through the Precipitator.

FIG.4. 7.1
INDUCED
DRAUGHT FAN MOTOR
FIG.4.7.2 INDUCED DRAUGHT FAN MOTOR-NAME PLATE
Working mechanism of ID FAN--Variable Frequency Drive (VFD): -
The Load Commutated Inverter (LCI) is static, adjustable frequency drive system that controls a
synchronous machine form near to rated speed. The basic system consists of line commutated,
phase-controlled thyristor converter that. feeds a load commutated thyristor convertor through a
dc link reactor is a simplified one-line diagram of a single channel LCI. The transformer
provides isolation from the ac system bus and provides the correct voltage at the terminals of
the rectifier.
Also, the internal impedance of the transformer limits the magnitude of any downstream bus
faults. The rectifier is a thyristor bridge whose gating is controlled to produce a variable dc
voltage at its [Link] output of the rectifier is fed through the dc link reactor, whose function

24
is to smooth the current and keep it continuous over the operating range of the system. The dc
link reactor output is then fed into the inverter bridge, which provides variable frequency ac the
stator terminals of the synchronous machine.
The inverter bridge and the rectifier bridge use the same power hardware and are controlled by
microprocessor- based electronics.
Although the bridges are labelled 'rectifier" and 'inverter,' It is possible for theit roles and hence
power flow to reverse. In this case the synchronous machine would be braked by pumping its
energy back into the ac line. A more general nomenclature is to call the line bridge the source
converter, and to call the machine side bridge the load converter.
The synchronous motor field is usually excited by a brushless exciter coupled to the motor
shaft. The brushless exciter is a wound rotor induction machine whose rotor voltage is rectified
to supply field current to the synchronous machine.

FIG4.7.3. Simplified
LCI One Line Diagram
The stator voltage for the brushless exciter is supplied from a static excitation voltage controller
included as part of the LC1 control panel. This controller Is gated/controlled entirely by tile
LC1 electronic control module. The LC1 controls the excitation to produce the required
machine flux and provides field over under current protection.
A more detailed diagram of an LC1 is shown the electronic control receives the following signal
inputs:
1. Attenuated line and load bus voltage signals.
2. Attenuated line and load current signals from current transformers
3. Speed reference signal.
4. Process commands such as stop, start, etc.
The attenuated bus voltage signals are used by the control to synchronize thyristor firing with
the line and load voltages, to provide voltage feedback, and over under voltage detection. The
25
 attenuated current signals are used for regulator current feedback, electronic over-current
detection, ad software-implemented fault detection.
The electronic control evaluates the process commands and 3nternalstatus signals to determine
whether the drive should be in a stopped, started, alarmed, or faulted condition. If in a started
condition, the electronics provides gate signals to control the thyristor bridges and the excitation
voltage controller. These signals are low level and are conditioned in the power bridge circuitry
to provide the necessary isolation and power level.

FIG4.7.4:LCI
DRIVE

4.8. HP MOTOR
a) Specifications: -
KW 400
DUTY CONTINUOUS
CONNECTION STAR
RATED 1483 RPM
SPEED
RATED 3300 VOLTS
VOLTAGE
FREQUENCY 50 HZ

26
 RATED 85 AMPS
CURRENT
MAKE MARATHON
POWER 0.87
FACTOR
EFFICIENCY 94.5%
TABLE 4.8 SPECIFICATION OF HP FAN

b) FUNCTION: Slurry wastes from the mills and boiler is pumped out to the slurry tanks using
HP Motor

FI
G.4.8. HP MOTOR

4.9. AUXILLARY COOLING WATER PUMP MOTOR

a) Specifications:
KW 400
DUTY CONTINUOUS
AMBIENT 50*
TEMP.
RATED 1483 RPM
SPEED
RATED 3300 VOLTS

27
 VOLTAGE
FREQUENCY 50 HZ
RATED 88 AMPS
CURRENT
MAKE C.G. L
POWER 0.84
FACTOR
EFFICIENCY 94.5%
TABLE 4.9 SPECIFICATION OF AUXILLARY COOLING WATER PUMP

b) FUNCTION: It drives the pump that circulates cooling water to auxiliary equipment like
bearings, heat exchangers, and generators. This helps in removing excess heat and maintaining
safe operating temperature of plant components.

[Link] MOTOR&NAME PLATE

4.10. TRANSPORT AIR COMPRESSOR (TAC)MOTOR
a) Specifications:

KW 280
PHASE 3
MAKE MARATHON
AMBIENT 50*
TEMP.

28
 RATED 1498 RPM
SPEED
RATED 3300 VOLTS
VOLTAGE
FREQUENCY 50 HZ
RATED 86 AMPS
CURRENT
CONNECTION STAR
POWER 0.85
FACTOR
EFFICIENCY 95%
TABLE 4.10 SPECIFICATION OF TAC MOTOR

b) FUNCTION: It drives the compressor that supplies compressed air for transporting coal ash
or fuel in the plant. This helps in smooth material handling and efficient operation of the system.

29
 FIG. 4.10 TAC MOTOR-NAME PLATE
4.11. DMCW-TG MOTOR
RATINGS
KW 200
QUANTITY 03
FRAME SIZE ILA7500-
4
AMBIENT 50*
TEMP.
RATED 1481
SPEED RPM
RATED 3300
VOLTAGE VOLTS
FULL LOAD 45 AMPS
CURRENT
NO-LOAD 15 AMPS
CURRENT
RATED 50 Hz
FREQUENC
Y
POWER 0.8
FACTOR
EFFICIENCY 93%
Table4.11: -Ratings of DMCW-TG Motor

b) FUNCTION: Large steam-powered turbo generators provide most of the world's electricity.
The availability of power plants depends crucially on the reliability of key assets such as the
Isolated phase bus, the transformer, and the generator. An electrical or mechanical failure of a
turbo generator can cause severe damage, resulting in a long period of downtime and significant
loss of revenue.
4.12. DMCW-SG MOTOR: -

30
a) FUNCTION: Steam generators are heat exchangers used to convert water into steam from
heat produced in a nuclear reactor core. They are used in pressurized water reactors (PWR)
between the primary and secondary coolant loops. In typical PWR designs, the primary coolant
is high-purity water, kept under high pressure so it cannot boil. This primary coolant is pumped
through the reactor core where it absorbs heat from the fuel rods. It then passes through the
steam generator, where it transfers its heat (via conduction through metal) to lower-pressure
water which is allowed to boil.
RATINGS:
KW 225
QUANTITY 02
FRAME SIZE ILA7502-
4
AMBIENT 50*
TEMP.
RATED 1483
SPEED RPM
RATED 3300
VOLTAGE VOLTS
FREQUENC 50 HZ
Y
FULL LOAD 50AMPS
CURRENT
NO-LOAD 18 AMPS
CURRENT
POWER 0.84
FACTOR
EFFICIENCY 93.2%
TABLE 4.12. RATINGS DMCW-SG MOTOR

31
 FIG. 4.12 DMCW MOTOR

4.13. INSTRUMENTAIR COMPRESSOR (IAC) /SERVICE AIR COMPRESSOR (SAC)

MOTOR

FIG
4.13 IAC MOTOR-NAME PLATE

a) Specifications:
KW 400
QUANTITY 02
INSULATION F
CLASS
AMBIENT 50*
TEMP.
RATED 1490 RPM
SPEED
RATED 3300 VOLTS
VOLTAGE
FREQUENCY 50 HZ
RATED 86A
CURRENT
DUTY CONTINUOUS
MAKE MARATHON
POWER 0.86
FACTOR
EFFICIENCY 95%

32
 TABLE 4.13 SPECIFICATION OF IAC/SAC MOTO

4.14. BOILER CIRCULATING WATER PUMP (BCW) MOTOR

a) Specifications:
K 4
W 5
0
Q 0
U 2
A
N
T
I
T
Y

I Y
N
S
U
L
A
T
I
O
N

C
L
A
S
S
A 5
33
M 0
B *
I
E
N
T

T
E
M
P
.

R 1
A 4
T 7
E 2
D
R
S P
P M
E
E
D

R 3
A 3
T 0
E 0
D
V
V O
O L
L T
T S
34
A
G
E

F 5
R 0
E
Q H
U Z
E
N
C
Y

R 1
A 0
T 9
E .
D 4

C A
U
R
R
E
N
T
D C
U O
T N
Y T
I
N
U

35
 O
U
S
M M
A A
K R
E A
T
H
O
N
P 0
O .
W 8
E 4
R

F
A
C
T
O
R
E 8
F 7
F %
I
C
I
E
N
C
Y

36
 TABLE 4.14 SPECIFICATION OF BCW MOTOR

[Link] MOTOR

b) FUNCTION: At high pressure, density difference between water and steam is very low. So
Natural circulation in boiler is not possible. To induce circulation additional pressure is required
4.15 HT MOTORS ABOVE 200KW&APPLICATIONS
List Of HT motors above 200KW
Motor Design Data
Details Voltage(V) Current(A) Power PF Efficiency
(KW)
DMCW SG 3300 +10% 50 225 0.84 93.2
DMCW TG 3300 +10% 45 200 0.84 93.0
TAC 3300 +10% 60.5 280 0.85 95.0
SAC/IAC 3300 +10% 86 400 0.86 95.0
BCW(CC) 3300 +10% 109.4 450 0.84 87.0
ACW 3300 +10% 88 400 084 94.5
CW 11000+10% 154 2250 0.80 96.0
Table4.15: -List of HT Motors above 200KW

37
 5. MOTOR MAINTENANCE
5.1 OBJECTIVES
• Perform routine inspection and maintenance checks of three-phase motors.
• Perform the following simple tests:
 measure insulation resistance
 use a growler to locate short-circuited coils continuity checks for open-circuited coil
 balance test to determine phase currents under load speed variation
• Replace and lubricate sleeve and anti-friction bearings, according to manufacturer’s manual.
• Lubricate motors, according to manufacturer’s manual.

PREVENTIVE MAINTENANCE SCHEDULE FOR HT MOTORS

[Link] LIST OF ACTIVITIES PERIODICITY
.
I) 11KV and 3.3KV HT Motors:
4-6Years
1 Overhaul of the motor.

2 Checking of Terminal Tightness of motor T.B and AOH/

Neutral box Emergencies
3
Lubrication of the HT motors Quarterly
4
Checking of Vibration readings of the motor 15Days
5
Checking of IR Values of the Motors AOH/
6 Emergencies
38
 Checking, Cleaning and Testing of Cooler of the
7 motor AOH/ Need Based

8 Cleaning of Mill, FD, PA, ID Motors Twice in a week

Cleaning of CEP, SG/TG DMCW, MDBFP, SAC,

15Days
IAC, TAC, HP Motors.
9
Cleaning of CWP, ACWP Motors
15Days

Table: -5.1Preventive Maintenance Schedule for HT Motors

Most electrical equipment requires planned inspection and maintenance to keep it in proper
working condition. Periodic inspections prevent serious damage to machinery by locating
potential trouble areas. Observant personnel will make full use of their senses to diagnose and
locate problems in electrical machinery: the sense of smell directs attention to burning
insulation, the sense of touch detects. Excessive heating in windings or bearings, the sense of
hearing detects excessive speed or vibration, the sense of sight detects, Excessive sparking and
many mechanical faults.
5.2 PERIODIC INSPECTIONS
The ideal motor maintenance program aims at preventing breakdowns rather than repairing
them. Systematic and periodic inspections of motors are necessary to ensure best operating
results. In a good preventive maintenance program with detailed checks, the person in charge
should have a record card on file for every motor in the plant.
Entries on the card should include inspection dates, descriptions of repairs, and the costs
involved. When the record indicates that a motor has undergone excessive and /or costly repairs,
the causes can be determined and corrected.
Inspection records also serve as a guide to indicate when motors should be replaced because of
their high cost of operation. They also reveal faulty operating conditions, such as misapplication
or poor drive engineering.
Inspection and servicing should be systematic. However, the frequency of inspections and the
degree of thoroughness may vary, as determined by the plant maintenance engineer. Such
determinations are based on
1. The importance of the motor in the production scheme
2. If the motor fails, will production be slowed seriously, or stopped
3. The percentage of the day the motor operates,
4. The nature of the service, and
5. The motor’s environment.

39
TWICE A WEEK
Cleaning of Mill, FD, PA, ID Motors
EVERY WEEK.
1. Check oil level in bearings.
2. See that oil rings turn with shaft.
3. See that exposed shaft is free of oil and grease from bearings.
4. Examine the circuit breaker, CTs and other controls, tighten loose connections.
5. See that the motor is brought up to speed in normal time.
6. Clean motor thoroughly, blowing out dirt from windings, and wipe.
EVERY 15 DAYS
1. Checking of Vibration readings of the motor
2. Cleaning of CEP, SG/TG DMCW, MDBFP, SAC, IAC, TAC, HP Motors.
3. Cleaning of CWP, ACWP Motors

EVERY THREE MONTHS

1. Lubrication of the HT motors

5.3 LUBRICATION
Several methods of lubricating motors are used. Small motors with sleeve bearings have oil
holes with spring covers. These motors should be oiled periodically with a good grade of
mineral oil. Oil with a viscosity of 200 seconds Say bolt (approximately SAE 10) is
recommended.
The bearings of larger motors often are provided with an oil ring which fits loosely in a slot in
the bearing. The oil ring picks up oil from a reservoir located directly under the ring. Under
normal operating conditions, the oil should be replaced in the motor at least once a year. More
frequent oil replacement may be necessary in motors operating under adverse conditions. In all
cases, avoid excessive oiling; insufficient oil can ruin a bearing but excessive oil can cause
deterioration of the insulation of a winding.
Many motors are lubricated with grease. Periodic replacement of the grease is recommended. In
general, the grease should be replaced whenever a general overhaul is indicated, or sooner if the
motor is operated under severe operating conditions.
Grease can be removed by using a light mineral oil heated to 165° For a solvent. Any grease-
removing solvents should be used in a well-ventilated area.

 Ball Bearing Lubrication:

40
The following table indicates recommended intervals between the regreasing of ball bearing
units. It is important that the correct amount and type of grease be used in ball bearings. Too
much grease can cause overheating. Fractional horsepower motors often contain sealed
bearings. With normal service, these bearings don't require regreasing. When regreasing is
required for unshielded bearings, the manufacturers ‘specifications and directions must be
followed.
Some motors with ball bearings are provided with pressure fittings and a grease gun is used to
lubricate the bearings. Remove the bottom plug when doing this. Because of the wide variation
in the design of industrial motors, the electrician should consult the comprehensive lubrication
manuals published by electrical machinery manufacturers to insure the proper lubrication of all
types of motors

BALL AND ROLLER BEARING MAINTENANCE

 Cleaning Out Old Grease
It is best to remove the bearing, if possible. However, when cleaning a bearing in place, remove
as much of the old grease as possible, using a rag or brush free from dirt or dust. Flush out the
housing with clean, hot diesel (110 F to 125° F); clean, new oil; or solvent. After the grease has
been removed, flush out the bearing with light mineral oil to prevent rust and to remove all
traces of cleaning fluid. Allow to drain thoroughly before adding new grease.
When the bearing is removed from the case, wash out the hardened,
Rancid grease from the housing and bearing as follows:
1. Put on safety glasses, or a face shield, for protection.
2. Soak the bearing in hot diesel, then remove it.
3. Rotate the bearing slowly by air hose. (Fast rotation may score the balls without lubrication.)
4. Dip the bearing in clean diesel, light oil, or solvent.
5. Rotate the bearing slowly again by air hose.
6. Wash the bearing again with clean diesel or solvent.
7. Rotate the bearing in hand, and check for smoothness.
8. If the bearing is smooth, repack it with grease.
9. If the bearing isn't smooth, but is in good condition, there is still some hardened grease in it.
Repeat operations 6 and 7.
 Lubricating Bearings with Pressure Relief Plug
41
1. Wipe fitting and plug clean.
2. Remove relief plug in bottom of bearing.
3. With shaft in motion (if possible), force grease into the top grease fitting, catching old grease
in a pan. Add grease until new grease appears at the pan.
4. With a screwdriver, open the relief hole. Don't push the screwdriver into the gearing housing.
5. Allow bearing to run with relief plug out to remove pressure.
6. After the grease stops running out, and there is no longer any pressure in the bearing, replace
the relief plug.
 Lubricating Bearings without Relief Plug.
1. Install grease fitting with safety vents.
2. With the motor running, pump in grease slowly until a slight bleed shows around the seal or
safety vent.
3. If necessary to lubricate while bearing is standing, fill the bearing with grease from one-
fourth to one-half of its capacity.
NOTE: It is important not to over grease, and grease must be kept clean.
 Re-lubrication with Oil
Oil is always subject to gradual deterioration from use, and contamination from dirt and
moisture. Because of this, regular intervals for cleaning bearings must be maintained.
1. After draining the used oil, flush out the bearing. This can be done by using a new charge of
the lubricant used for regular lubrication. Run the machine for three to five minutes, and drain
again. Units used where there is sawdust or dirty conditions may require two flushing’s.
2. Fill with new oil to the proper level. Be sure new oil is from a clean container, and that no dirt
is pushed into the filler plug while filling.
Lubricant must be kept clean.
3. Check the seals to see that they are effective to prevent leakage or the entry of outside dirt to
the bearing. It is important to keep the lubricant clean and the bearing flushed out so that it will
be clean.
Always read and follow the manufacturer’s instructions whenever possible

42
 6. SWITCH GEAR

6.1 DEFINTION OF SWITCHGEAR

SWITCH-GEAR: - Switch gear is a control switch that controls the operation of a power
circuit. It is a combination of fuses, circuit breakers, switches used to control, protect and isolate
electrical equipment. Switchgear is used both to energize equipment to allow work to be done
and to clear faults downstream
The two functions of a switch in power systems are: -
i) To permit the transmission lines to be convenient put into and taken out from service.
ii) To disable some plant and lines when these become faulty. To be rapidly and safety isolated
by
automatic means.
The first of these can be served by relatively simple switches the second however require circuit
breakers, which are more robust & capable of breaking the large value of fault power that
results in faults on major power system since all plants and lines are liable to develop faults as a
result of mechanical damage, electrical breakdown, errors in operation etc. The simple isolators
switch in favor of automatic circuit breakers even for switching function. The whole switchgear
assembly consists of two parts:
A) PANEL
B) TROLLEY
43
These two parts are briefly explained below with the help of diagram
A) PANEL: Panel consists of protective relays. Mounting of potential transformer, current
transformer, ammeter, voltmeter & energy meter. The potential transformer is mounted on the
panel. The primary is connected to 11KV & the reduce voltage from the secondary is given to
energy meter as line voltages & for protective purposes.

FIG 6.1.1 PANEL

B) TROLLEY: - The trolley consists of current carrying contracts called electrodes. These are
normally engaged but in predetermined conditions. Separate to interrupt the circuit, when the
contact is made.

FIG 6.1.2. TROLLEY

6.2 PARTS OF SWITCHGEAR
RELAY CHAMBER
In KTPP power plant Numerical relays are used. Numerical relays are used due to its
advantages which are explained below.
a) NUMERICAL RELAY:
Numeric relays are programmable relays where the characteristics and behaviour can be
programmed. It is a device in which measured electrical quantities are sequentially sampled and
then converted into numerical data which are mathematically or logically processed to take
decision for issuing trip command.

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 FIG
6.1.3. NUMERIC RELAY
Advantages of numerical relays
 Compact size
 Flexibility
 Reliability
 Multi-function capability
 Different types of relay characteristics
 Digital communication capabilities
 Modular frame
b) PROTECTION SETTINGS:
The protection settings include all the following items that become active once enabled in the
configuration column of the relay menu database.
 Thermal overload protection
 Short circuit protection
 Sensitive earth fault protection
 Negative sequence over current
 Three phase voltage check
VACUUM INTERRUPTER: Vacuum interrupters are used in circuit breakers to conduct and
to interrupt normal current at system voltage and for making and breaking fault currents. They
are reliable, maintenance free and offer several advantages:
 High and consistent dielectric strength of vacuum, unaffected by environment and switching
operations
 Brazed joints ensure retention of vacuum for lifetime.
 Low and stable contact resistance due to absence of
oxidation effects, there by low power loss.

45
 FIG4.4 VACUUM INTERRUPTER

OPERATION OF BREAKER GENERAL

The operating mechanism is stored energy type. The operating mechanism has three helical
springs to store energy for closing, tripping and maintaining desired contact pressure
The motor is of fractional horsepower type which can be operated through supply of station
battery (DC) or through' auxiliary supply (AC). Standard station voltages are 24 VDC, 30 VDC,
48 VDC, 110 VDC and 220 VDC. Motors are universal type which can run either on AC or DC.
Charging time of motor is 15 sec (max).

7. HT SWITCH BOARDS
This Report provides general guidelines for the proper maintenance of electrical switchgear
used in postal facilities. Specific models of switchgear apparatus are not described in detail
cause of the large variety of models available. Rather, maintenance information is presented for
five classes of switchgear equipment:
KTPP STAGE-II (1x600 MW) consist of 11 No’s of Switchboards.
1) 2BA Board
2) OBA Board
3) OBB Board
4) 2BB Board
5) OBX Board
6) 2CA Board
7) 2CB Board
8) OCA Board
9) OCB Board
10) 11KV Silo Board
11) 3.3 KV AHP Board

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 12. OBA [Link]

14.2BA 15.2BB
Fig 7.1 SWITCHGEAR BOARDS

The above boards will cater the all required loads of the plant. OBA & OBB boards will charge
by Station Transformer of Capacity 80 MVA and 2BA & 2BB boards will charge by 270MVA
single phase generator transformers. 2CA & 2CB boards will charge by through unit service
transformers. OCA & OCB boards will charge by station service transformers. OBX board will
cater the loads whenever 80MVA station transformer is out of service.
Line potential transformers will be provided at switchgear end to monitor the voltage levels of
transformers. Whenever incomer breaker charged the supply will be extended throughout the
bus. The bus voltage will be measured by bus potential transformers provided at one of the
modules in the board.
The different types of feeders having different logical schemes in the control circuit to operate
the breaker. Depending upon the necessity of the outgoing the corresponding breaker will be
charged.
7.1TYPES OF FEEDERS:
 Incomer:

47
Each board having one incomer. These incomers will feed the corresponding board and these
incomers will be charged by corresponding transformers like station transformers, unit
transformer, station auxiliary transformer and unit auxiliary transformer and some service
transformers. Whenever corresponding transformers are in charged condition the line voltage
will be extended through bus ducts towards the board until unless close the incomer then only
board will be charged. The logic will be implemented on each and every board only either
incomer or tie will be in on condition.

7.1.2. INCOMER

 Tie: Whenever incomers fail to feed the corresponding board then tie will be ON in auto
model to maintain the bus voltage. The PSL logic will be implemented whenever any faults
occur towards the transformer end then incomers will be tripped. At that time tie will be ON in
synchronization mode.

7.1.3. TIE
 Outgoing to motor
Whenever bus is in charged condition bus side voltage will be extended and is attached to
trolley. The female contact of trolley will sit on bus. Whenever the corresponding outgoing is
in ON condition then supply will be extended to motor
which is located at corresponding locations through
cables.

48
 Fig 7.1.4. OUTGOING TO MOTOR

 Outgoing to transformers
Whenever bus is in charged condition bus side voltage will be extended and is attached to
trolley. The female contact of trolley will sit on bus. Whenever the corresponding outgoing is in
ON condition then supply will be extended to motor which is located at corresponding locations
through cables.

Fig 7.1.5 OUTGOING TO TRANSFORMER

Bus duct
Here in KTPP two types of bus ducts are using. One is ISOLATED PHASE BUS DUCT (IPBD)
and second one is SEGREGATED PHASE BUS DUCT(SPBD). Bus duct will carry the highest
amount of current and they will feed the corresponding incomers from transformer.

49
 FIG.7.1.6 SPBD FIG.7.1.7 IPBD

8. MAINTENANCE OF SWITCHGEAR
8.1 Need for Maintenance
Benefits of Maintenance: Only a program of electrical apparatus testing under simulated or
actual operating conditions combined with regularly scheduled preventive maintenance will
ensure the reliability of electrical switchgear. Conclusive electrical tests, properly applied, will
determine if equipment is operating properly, if it needs repair, or if it should be replaced with
newer apparatus. Regularly scheduled preventive, predictive, and reliability centered
maintenance has many benefits. It permits more than a routine inspection of equipment and
allows time for more thorough maintenance to be performed. Equipment can be cleaned,
inspected, lubricated, mechanically checked, and operated. Thorough maintenance results in
improved system performance, higher reliability, and a reduction in the number of unexpected
problems that can occur on poorly maintained equipment. Properly planned component testing
in coordination with scheduled maintenance ensures electrical protective devices operate as
designed when a power anomaly occurs. Device testing should be completed using up-to-date
industry processes and testing equipment.
8.2 Elements of an Effective Maintenance Program: A number of elements are required to
establish and operate an effective maintenance program for electrical switchgear. These
elements are:
a.A thorough knowledge of the facility switchgear and distribution equipment and its
characteristics, including one-line and control diagrams and assorted other documentation.
b. Adequate familiarization training for employees operating electrical switchgear.
c. Sufficient properly trained personnel to perform authorized maintenance tasks.
d. Coordination between all functional areas within a facility, particularly in regard to
scheduling of equipment down time.

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EARTHING THROUGH EARTHING TRUCKS
Earthing is a very essential to safeguard from high voltage shock to maintenance personnel. If
maintenance work is to be carried out on the feeder side only then earthing has to be done
through feeder earthing truck. Feeder earthing truck has got only bottom jaw contacts.
Therefore, no possibility of touching bus bar side live position. This is achieved by taking out
main VCB tuck and then inserting feeder earthing truck

FIG8.2. EARTHING TRUCK

If maintenance is to be carried out on bus side of switchboard, bus earthing has to be done
through Bus earthing truck. Since all bus bars are joined together, precaution has to be taken to
ensure all possible sources are disconnected. To achieve this, bus earthing truck is allowed to be
instead into specified panel only. Also, mechanical interlock arrangement is planned in such a
way that top jaw contacts only therefore no possibility of touching the feeder side.
In both feeder and bus earthing trucks all three phases of other sides are shorted together and
finally joined to earthing strips of the earthing trucks. When inserted for earthing, this strip
engages with panel earthing strips.

8.3 SLOW CLOSING AND OPENING OPERATION:

 CLOSING OPERATION
CONDITION AT THE BEGINNING
Circuit Open
breaker
Closing Discharged
spring
Motor Disconnected
supply
Tripping Discharged
spring
TABLE 8.3.1 CLOSING OF C.B

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Open the cover of spring mechanism and place slow closing handle between operating shaft and
pin extension. Firmly hold the slow closing handle with both hands and press it downwards
until contact’s touch. Now the pressure required to further press the handle down will be
substantially higher as it compresses the contact pressure spring until the trip pawl latches with
trip lever roller and the mechanism is latched in closed position. The mechanical position
indicator will show ON.
 SLOW OPENING OPERATION
CONDITION AT THE BEGINNING
Circuit Closed
breaker
Closing Discharged
spring
Motor Disconnected
supply
Tripping Charged
spring
Contact Charged
pressure
spring
TABLE 8.3.2 OPENING OF C.B

Position the slow closing handle as described above for slow closing operation and further
process it downward in closing direction. Ask a colleague to press the manual trip knob or trip
coil plunger to disengage the trip pawl from trip roller. The tripping spring energy will be
released but restrained due to downward pressure on handle by operator. Slowly release the
pressure from slow closing handle by moving handle in upward direction, allowing the
operating shaft to rotate and thereby opening the breaker contacts.
The mechanical position indicator will show OFF. The trip damper levers on operating shaft
will compress the trip dashpot.

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 FIG 8.3. SLOW CLOSING AND OPENING OPERATION

8.4 INSPECTION OF VACUUM LEVEL

Before putting the vacuum breaker in service or if interrupter is suspected of leaking due to
mechanical damage, the vacuum level shall be checked as below: -
(A)Open and isolate the breaker and detach the insulated coupler from lever.
(B) The atmospheric pressure will force the moving contact of a hermetically sealed interrupter
into the close position. A vacuum interrupter may be assumed to be intact if it shows the
following characteristics:
An appreciable closing force has to be overcome when lever is moved to the ‘open’ position by
hand. When the lever is released, it must automatically return to the ‘close’ position and the
contacts must be heard to close with metallic sound. After checking the vacuum, the lever
should be refitted to the insulated coupler.

FIG.8.4INSPECTION OF VACUUM LEVEL

8.5 LUBRICATING OF OPERATING MECHANISM:

53
The points to be lubricated with Cento plex 20DL or Malykoteor WD40are marked. Other
locations like bearing, articulated joints and auxiliary switch should be treated with malykote
spray.
To lubricate the mechanism parts, remove its cover. Articulated joints and bearings that cannot
be dismantled should be cleaned with cleaning agent prior to being oiled. Lubricate all
appropriate points, starting at the top left and working systematically. Parts that are not rigidly
fixed. After lubrication operate the breaker several times to set it.

CONCLUSION
Kakatiya Thermal Power Plant (KTPP) efficiently generates electricity using coal through the
coordinated operation of boiler, turbine, and generator. Electrical protection systems ensure safe
and reliable functioning of the plant. Proper maintenance improves performance and lifespan of
equipment. Here H.T motors are mainly used for only high voltage applications (like 11kV &
3.3kV). In industrial applications we can use these high-tension motors. In this planet except for
small loads (like lights, fans & small load motors). The remaining total motors and fans are of
high-tension motors.
In the conditional monitoring, we test the equipment to avoid the forced outage If faults are
found to be occurring outages can be planned and the fault can be rectified before major occur.
With strict monitoring, accurate diagnostics interpretations and realistic
operational/maintenance
 Strategies implementation the following would be achieved effectively.
 Asset economic loading conditions identification and assessment for maximum practicable
operating efficiency.
 Premature failures risk minimization
FUTURE SCOPE
The future scope of KTPP includes improving efficiency through modern equipment and
advanced protection systems. Adoption of cleaner technologies can reduce environmental

impact. Better maintenance and monitoring can enhance performance . The adoption of modern
electrical protection systems and improved monitoring techniques can enhance safety and
reliability. Environmental impact can be reduced by implementing cleaner technologies and
54
 effective pollution control methods. In addition, advanced maintenance practices can minimize
breakdowns and improve overall performance. Integration of renewable energy sources along
with thermal power generation can also support sustainable and efficient power production.

REFERENCES
 [Link] , [Link], and P. Kumaran
“An Overview of Protection Systems in a Thermal Power Plant,”Malaya Journal of Matematik,
vol. 8, no. S, pp. 485–489, 2020

 R. Karthikeyan, S. Balaji, and V. Prakash,

“Advancement in Protection Systems in a Thermal Power Plant,” International Journal of
Engineering and Advanced Technology (IJEAT),vol. 8, no. 6S2, pp. 128–132, 2019

 Z. Q. Bo, J. H. He, and X. Z. Dong,

“Developments of Power System Protection and Control,” Protection and Control of Modern
Power Systems,vol. 1, no. 1, pp. 1–10, 2016.

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