NATIONAL ALUMINIUM COMPANY
VOCATIONAL TRAINING REPORT
CAPTIVE POWER PLANT, NALCO, ANGUL
GUIDED BY: SUBMITTED BY:
Mr. YOGESH KUMAR TIWARI NAME: SOLEN P SILVA
DEPUTY MANAGER(ELECTRICAL), ROLL NO: 2107018
CPP DIVISION, ANGUL SEMESTER: 4th
BRANCH: ELECTRONICS AND
ELECTRICAL ENGINEERING
INTRODUCTION
❖ National Aluminium Company Limited (NALCO) is a Navratna CPSE under the
Ministry of Mines, Govt. of India. It was established on 7th January 1981, with
its registered office at Bhubaneswar. At present, the Government of India
holds 51.28% of paid-up equity capital.
❖ Alumina Refinery is located at Damanjodi, Odisha, approximately 14 km from
the bauxite mine at Panchpatmali. The mined-out bauxite is transported from
the captive mine to the refinery by a 14.6 KM long single-light multi-curve
1800 tonnes per hour (TPH) capacity cable belt conveyor. The alumina
produced is transported to the aluminum smelter at Angul (Odisha) and to
Vizag (Andhra Pradesh) port by rail.
❖ Aluminium Smelter The present capacity of the smelter is 4.60 lakh TPA.
Alumina is converted into primary aluminum through a smelting process by
using electrolytic reduction. From the pot line, the molten aluminum is routed
to either the casting units, where the aluminum can be cast into ingots, sow
ingots, tee ingots, or billets. wire rods, cast strips, and alloy ingots, or to RPU
where the molten aluminum is rolled into various cold-rolled products or cast
into aluminum strips. Aluminum products are sold in the domestic market and
also exported through Kolkata, Paradeep & Vizag ports.
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CAPTIVE POWER PLANT
CAPTIVE POWER PLANT (CPP) has a generation capacity of 1200 MW
(10X120MW). While the captive thermal power plant provides the entire
electric power requirement of the aluminum smelter, it also feeds for
approximately 35 MW of the power requirement to the alumina refinery
through the State Grid. The location of the captive thermal power plant at
Angul is also strategic to the availability and supply of coal from nearby
Talcher Coalfields. The 18.5 KM captive railway system links the captive
thermal power plant to the Talcher coalfields, enabling transport of the
critical and bulk requirement of coal.
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SALIENT FEATURES OF CPP:
❖ Micro-processor-based burner management system for optimum
thermal efficiency.
❖ Computer-controlled data acquisition system for on-line monitoring.
❖ Automatic turbine run-up system Specially designed barrel-type
high-pressure turbine
❖ Advanced electrostatic precipitator (99.9% efficiency) to control
pollution.
❖ Wet disposal of ash with High Concentrate Slurry Disposal (HCSD)
System for ash disposal.
❖ Zero discharge of effluents and High plant load factor.
❖ The water for the Plant is drawn from River Brahmani through a 7 km
long triple circuit pipeline. The coal demand is met from a mine of 3.5
Million TPA capacity opened up for Nalco, initially at Bharatpur in
Talcher by Mahanadi Coalfields Limited.
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COMPONENTS OF CAPTIVE POWER PLANT:
❖ Coal Handling Plant
❖ Draft or Draught fan
❖ Boiler
❖ Turbine and Generator
❖ Superheater and Reheater
❖ Condenser
❖ Cooling Tower and Ponds
❖ Pulverizing Plant
❖ Ash Handling Plant
❖ Feed Water Heater
❖ Economiser
❖ Air preheater
❖ Alternator with Exciter
❖ Protection and control equipment
❖ Instrumentation
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❖ Coal Handling Plant :
This includes storage facilities for the fuel used to power the captive
power plant, such as coal, natural gas, diesel, or biomass. It may involve
storage tanks, silos, or other storage arrangements. Fuel-handling
equipment like conveyors, crushers, and feeders may also be present.
❖ Draft or Draught fan :
● The combustion in the boiler requires a
supply of sufficient quality air and the
removal of exhaust gases.
● The Circulation of air caused by a
difference in pressure is known as
draught. Thus draught is the differential
in pressure between the two points.
● A draught tube may be :
1. Natural Draught
2. Mechanical Draught
❖ Boiler :
A boiler (or steam generator) is a closed vessel in which water, under
pressure, is converted into steam. The heat is transferred to the boiler
by all three modes of heat transfer i.e. conduction, convection and
radiation.
Major types of boilers are:
1. fire tube boiler
2. water tube boiler
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❖ Turbine and Generator:
Turbines in thermal power plants are typically large and designed to
handle high temperatures and pressures. They play a crucial role in
converting thermal energy into mechanical energy, which ultimately
generates electricity for various applications. Steam entering from a small
opening attains a very high velocity.
There are two types of steam turbines:
1. Impulse
2. Reaction
The generator is connected to the
prime mover and converts the
mechanical energy produce into
electrical energy. It consists of a
rotating rotor and a stationary
stator, which work together to
generate electricity.
❖ Superheater and Reheater:
● Superheated steam is that steam which contains more heat than
saturated steam at the same pressure. The additional heat provides
more energy to the turbine hence power output is.
● Superheated steam causes lesser erosion of the turbine blades and
can be transmitted for longer distance with little heat loss
● The function of the superheater is to remove the last amount of
moisture from the saturated steam.
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❖ Condenser:
The function of the condenser is to condense the steam exiting the
turbine.
The condenser helps maintain low pressure at the exhaust.
Two types of condensers are used:
1. Jet Condensers
2. Surface Condensers
❖ Cooling System:
Captive power plants often require a cooling system to dissipate excess
heat generated during the power generation process. This can be
achieved through cooling towers, heat exchangers, or other cooling
methods, depending on the plant's design and requirements.
❖ Electrical System:
The electrical system includes components such as transformers,
switchgear, circuit breakers, and control panels to manage and distribute
the electricity generated by the captive power plant.
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❖ Control and Monitoring System:
Captive power plants have complex control and monitoring systems to
ensure efficient and safe operation. These systems include sensors,
programmable logic controllers (PLCs), human-machine interfaces
(HMIs), and supervisory control and data acquisition (SCADA) systems.
❖ Emission Control Equipment:
To comply with environmental regulations, captive power plants may
incorporate equipment for controlling emissions, such as electrostatic
precipitators (ESPs), bag filters, selective catalytic reduction (SCR)
systems, or other pollution control devices.
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❖ Auxiliary Systems:
These include various supporting systems necessary for the overall
functioning of the power plant, such as fuel supply systems, water
treatment systems, compressed air systems, fire protection systems, and
other utilities required for plant operations.
ELECTRICAL MAINTENANCE IN THE POWER PLANT:
SWITCHYARD MAINTENANCE:
A switchyard, also known as a substation, is a crucial component of
an electrical power system. Its primary function is to facilitate the
transmission and distribution of electrical energy from the power
generating stations to the end-users. The main functions of a
switchyard include:
a. Voltage Transformation: Switchyards often house transformers that
step up or step down the voltage levels of the electrical energy. This
voltage transformation is necessary for efficient transmission and
distribution of electricity over long distances and for matching the
voltage requirements of different electrical devices.
b. Switching Operations: Switchyards contain various types of
switches, circuit breakers, and disconnectors that allow for the control
and regulation of the flow of electricity. These devices are used to
connect or disconnect power lines, isolate faulty sections, and reroute
power as needed. Switching operations help in maintaining the
reliability and stability of the power system.
c. Protection and Control: Switchyards incorporate protection systems
that detect abnormal conditions in the power system, such as
overcurrent, overvoltage, and faults. These protection devices, such as
relays, are responsible for initiating appropriate actions, such as
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tripping circuit breakers, to isolate faulty sections and prevent damage
to the equipment or power system.
d. Monitoring and Metering: Switchyards may include monitoring and
metering equipment to measure electrical parameters such as voltage,
current, power factor, and energy consumption. This data is important
for operational analysis, billing purposes, and maintenance of the
power system.
e. Grounding and Safety: Switchyards provide proper grounding
systems to ensure the safety of personnel and equipment. Grounding
helps in diverting fault currents and mitigating the risk of electric shock
and damage due to electrical faults.
RELAY & BATTERY MAINTENANCE:
In a power plant, relays and batteries play crucial roles in ensuring the
reliable operation of electrical systems. Here's a more specific overview
of relay and battery maintenance in a power plant context:
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Relay Maintenance in Power Plants:
Regular Inspections: Conduct routine visual inspections of relays in
the power plant. Look for any signs of damage, overheating, loose
connections, or worn-out components. Pay special attention to critical
relays that are essential for protection or control functions.
Functional Testing: Perform regular functional testing of relays to verify
their correct operation. This can involve initiating test signals or using
specialized relay testing equipment to simulate fault conditions and
assess the relay's response. Document and keep records of these tests.
a. Calibration: Some relays may require periodic calibration to ensure
their accuracy. Follow the manufacturer's instructions for calibration
procedures and intervals. Use calibrated testing equipment to
perform these tasks.
b. Firmware/Software Updates: Keep the relay firmware or software up
to date with the latest versions provided by the manufacturer.
Updates often include bug fixes, performance improvements, and
enhanced functionality.
c. Cleaning and Dust Control: Maintain a clean environment to prevent
dust or debris from accumulating on relays. Regularly clean the relay
cabinets or enclosures to prevent contamination that can affect their
performance.
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Battery Maintenance in Power Plants:
Regular Inspections: Conduct visual inspections of batteries in the
power plant. Look for physical damage, leaks, corrosion on terminals, or
any other signs of deterioration. Inspect battery racks, trays, or containers
for structural integrity.
Electrolyte Levels: If the power plant uses flooded lead-acid batteries,
check the electrolyte levels regularly. Ensure they are within the
recommended range by adding distilled water if needed. Follow proper
safety precautions when handling and adding electrolytes.
a. Battery Testing: Perform regular battery testing, such as impedance
tests or load tests, to evaluate their capacity, internal resistance, and
overall health. These tests help identify weak or failing batteries that
may need replacement.
b. Temperature Monitoring: Monitor the ambient temperature in battery
rooms or cabinets. Excessive heat can accelerate battery aging and
reduce its lifespan. Implement cooling systems or ventilation to
maintain optimal temperature conditions.
c. Battery Equalization: If the power plant uses multiple batteries
connected in series, perform periodic battery equalization to balance
the charge levels across the batteries. This helps prevent capacity
imbalances and ensures uniform performance.
d. Replacement Strategy: Develop a battery replacement strategy
based on the manufacturer's recommendations and historical
performance data. Replace batteries at the end of their expected
lifespan or if they consistently fail capacity tests.
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MOTOR AND GENERATOR MAINTENANCE:
Maintenance of motor generators in a captive power plant is crucial for
ensuring their optimal performance, reliability, and longevity. Motor
generators are responsible for converting mechanical energy into
electrical energy, making them critical components of the power
generation system. Here are some key aspects of motor generator
maintenance in a captive power plant:
a. Regular Inspections: Conduct routine inspections of motor
generators to identify any signs of wear, damage, or abnormal
operating conditions. This includes checking for loose connections,
signs of overheating, unusual vibrations or noise, and inspecting the
condition of insulation
b. Lubrication: Proper lubrication of motor generator bearings and other
moving parts is essential to prevent friction and wear. Follow
manufacturer recommendations for lubrication intervals and use
appropriate lubricants.
c. Cleaning: Regularly clean the motor generator and its surrounding
areas to remove dust, debris, and any contaminants that can impact
its performance or cause overheating. Pay attention to cooling fins, air
vents, and filters to ensure proper airflow.
d. Electrical Testing: Perform regular electrical testing to assess the
motor generator's insulation resistance, winding resistance, and
overall electrical performance. This helps identify any potential issues
with insulation breakdown or electrical faults.
e. Balancing and Alignment: Ensure the motor generator is properly
balanced and aligned to minimize vibration and stress on the
components. Imbalanced or misaligned systems can lead to
premature wear and reduced efficiency.
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f. Bearing Maintenance: Monitor the condition of motor generator
bearings and perform periodic inspections and lubrication. If signs of
wear or damage are observed, bearings should be replaced promptly
to avoid further issues.
PH SWITCHGEAR MAINTENANCE:
Maintenance of switchgear is crucial for the reliable and safe operation
of a captive power plant. Switchgear is responsible for controlling,
protecting, and isolating electrical equipment and circuits within the
power system. Here are some key aspects of switchgear maintenance
in a captive power plant:
a. Visual Inspection: Regularly inspect switchgear for any signs of
damage, loose connections, overheating, or abnormal operating
conditions. This includes checking for corrosion, worn-out
components, and signs of arcing or sparking.
b. Cleaning: Keep switchgear and its surrounding areas clean to prevent
the accumulation of dust, dirt, and debris. Clean contacts, insulating
surfaces, and ventilation pathways to ensure proper operation and
heat dissipation.
c. Electrical Testing: Perform regular electrical tests to assess the
performance of switchgear. This includes measuring insulation
resistance, and contact resistance, and checking the operation of
protective relays. Testing helps identify any potential insulation
breakdown, loose connections, or faulty components.
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d. Functional Testing: Conduct periodic functional tests to verify the
proper operation of switchgear components, such as circuit breakers,
relays, meters, and control panels. This ensures that all protective
functions and control features are working as intended.
TRANSFORMER MAINTAINANCE:
Transformer maintenance is essential to ensure the reliable operation and
longevity of transformers, which are critical components in electrical
power systems. Proper maintenance practices help identify and address
potential issues early on, preventing costly breakdowns and reducing
downtime. Here are some key aspects of transformer maintenance:\
❖ Visual Inspection: Conduct regular visual inspections of the
transformer, both externally and internally if possible. Look for signs of
leaks, oil discoloration, corrosion, loose connections, or any physical
damage. Inspect the cooling system, bushings, tap changers, and
other components for any abnormalities.
❖ Oil Analysis: Transformer oil serves as an insulating and cooling
medium. Regularly collect oil samples and perform laboratory tests to
assess their quality. Oil analysis helps detect potential issues such as
moisture ingress, contamination, or degradation. Monitor parameters
such as moisture content, acidity, dissolved gas analysis (DGA), and
dielectric strength.
❖ Electrical Testing: Perform electrical tests to evaluate the
transformer's insulation system and overall health. These tests may
include insulation resistance measurement, polarization index testing,
winding resistance measurement, and transformer turns ratio
measurement. Electrical tests provide insights into the insulation
condition and identify any potential insulation degradation or faults.
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❖ Buchholz Relay Maintenance: If the transformer is equipped with a
Buchholz relay, ensure it is properly maintained. Inspect the relay for
proper oil level, proper functioning of gas and oil alarms, and any
abnormalities. Clean and test the relay as per manufacturer guidelines.
❖ Cooling System Maintenance: Check and clean cooling fans,
radiators, or heat exchangers to ensure optimal cooling efficiency.
Monitor coolant levels, pressures, and temperatures. Ensure that
cooling systems are free from debris or obstructions.
❖ Tap Changer Maintenance: If the transformer has an on-load tap
changer (OLTC), inspect and maintain its operation. Check for any
abnormalities, such as arcing, and ensure smooth and proper tap
changing. Clean and lubricate the tap changer mechanism as per
manufacturer guidelines.
❖ Bushing Inspection: Inspect bushings for any signs of cracks, leaks,
or contamination. Ensure that bushings are securely connected and
properly insulated.
❖ Protective Device Testing: Verify the operation and settings of
protective devices such as overcurrent relays, differential relays, or
temperature sensors. Test and calibrate these devices to ensure
accurate and reliable operation.
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GENERATOR AND ACTUATOR:
Generators are devices that convert mechanical energy into electrical
energy. They can be classified into different types based on their
operating principles, fuel sources, and applications. Maintenance is
essential to ensure reliable and efficient operation, and safety
precautions must be followed when working with generators.
An actuator is a mechanical or electromechanical device that converts
an input signal into physical motion or action. Actuators are used in
various applications, from industrial automation to robotics and
aerospace systems. They can be classified into different types based
on their operating principles and mechanisms, such as electric,
hydraulic, pneumatic, piezoelectric, and electroactive polymer
actuators.
Maintenance involves inspecting mechanical components, checking
electrical connections, calibrating position sensors, cleaning or
replacing filters, following manufacturer recommendations, monitoring
actuator performance, and adhering to any specialized maintenance
requirements. Proper maintenance and regular inspections are
essential to ensure reliable and efficient operation.
Types of Generator Protection:
● Excitor fail or loss of field protection - The generator acts as an
induction generator in this case.
● Field present but steam cut off or low forward power protection
or reverse power protection: The generator will act as a
synchronous motor. Generator rotor earth fault protection
● Generator stator protection
Generator GT protection:
● Over fluxing protection
● Over-frequency and under-frequency protection
● Over-voltage and under-voltage protection
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CONCLUSION
❖ Captive power plants play a significant role in meeting the energy
needs of industries and businesses. They offer several advantages,
including reliable and uninterrupted power supply, cost savings, and
reduced dependence on the grid.
❖ Captive power plants provide a reliable source of electricity, ensuring
uninterrupted operations for industries. This is particularly crucial for
sectors such as manufacturing, where any disruption in power supply
can result in substantial losses. By generating their own power,
businesses can maintain productivity and avoid downtime caused by
grid failures or load shedding.
❖ However, it's important to consider certain challenges associated with
captive power plants. Establishing and maintaining a captive power
plant requires a substantial upfront investment, including
infrastructure, equipment, and skilled personnel. Additionally,
businesses need to comply with relevant regulations and ensure
proper maintenance and operation of the power plant.
❖ Maintenance activities for captive power plants involve various
aspects, including routine inspections, preventive maintenance,
repairs, and equipment upgrades. By conducting routine inspections,
businesses can identify and address potential issues before they
escalate into major problems. This includes checking and servicing
the power generation equipment, monitoring fuel quality, and
assessing the condition of auxiliary systems.
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