Contents

• Objective
• Introduction
• Complete description of Power plant
• Coal Handling Plant
• Boiler
• Turbine
• Condenser
• Cooling Tower
• Turbo generator
• Transformer
• Switchyard
• Switchgear
• Communication
• Ash Handling plant (AHP)
• ESP
• Motors
• Safety
• Inference
• Reference
 Objective

The objective of this internship was to Explore career alternatives

prior to graduation. Integrate theory and practice. Assess interests
and abilities in their field of study. Learn to appreciate work and its
function in the economy. Develop work habits and attitudes
necessary for job success. Develop communication, interpersonal
and other critical skills in the job interview process. Build a record
of work experience. Acquire employment contacts leading directly
to a full-time job following graduation from college. Identify, write
down, and carry out performance objectives (mutually agreed upon
by the employer, the MCC experiential learning supervisor, and the
student) related to their job assignment.

INTRODUCTION

Damodar Valley Corporation (DVC) is a public sector company which

operates several power stations in the Damodar River area of West Bengal&
Jharkhand, India.
The company operates both thermal power station and hydel power dam
sunder the Indian Ministry of Power. The present capacity of DVC is 6357.2 MW
. The Damodar Valley Corporation has been generating and transmitting power
since 1953.
 Installed
Sr. Capacity in
No. City State MW

Bokaro Thermal Power

1 Station B Jharkhand 630

Chandrapura Thermal
2 Power Station Jharkhand 890

Durgapur Thermal Power West

3 Station Bengal 350
Durgapur thermal power station
West
4 Bengal 1000

Mejia Thermal Power West

5 Station Bengal 2,340

Koderma Thermal Power

6 Station Jharkhand 500+500

Raghunathpur Thermal West

7 Power Station Bengal 1200

Bokaro Thermal Power

8 Station- A Jharkhand 1200
 DVC-RTPS

Raghunathpur Thermal Power Station (RTPS) is located at Bokaro district in

the State of Jharkhand. It has five working unit with a total installed capacity
of 1200 MW. All of the units are coal-based. RTPS had the pride of being
largest pulverized fuel fire power station of Asia and unit number one was
the first reheat unit installed in India with highest steam parameters.
Electrical switchyard of RTPS is a pride of DVC, being India’s 2nd biggest
network.

Technical Aspects
INSTALLED CAPACITY: - Total Units - 5 Nos.
➢ 3 X 130 MW (U#1,2&3)
➢ 2 X 250 MW (U#7&8)
• Total Energy Generation: - 12000 MW
• Source of Water: - Damodar River
• Types of Fuel used: - Coal, LDO & HFO
• Sources of Coal: - B.C.C.L and C.C.L
• Sources of Oil: - Indian Oil

Project Cost
The approved cost of Unit 7 & 8 (2 X250 MW) is Rs. 2500 Crore.
(The current production cost is approx
Rs. 3.50/KW)
 OVERVIEW OF A THERMAL POWER PLANT

Simplified Diagram

PA fan – Primary Air fan

FD fan- Forced Draft fan
ID fan- Induced Draft fan
ESP- Electrostatic Precipitator
CEP- Condensate Extraction Pump
BFP- Boiler Feed Pump
GSC- Gland Steam Cooler
LPH – Low Pressure Heater
DA- Deaerator
HPH- High Pressure Heater
OAC- Open Approach Channel
RAH- Regenerative Air Heater
DM water- De-Mineralized water

The coal from mines is received at track hopper in CHP through Wagons. The unloaded coal
(max. size 250 mm2) is scooped into conveyor by Rotary Plough Feeders & is passed
through suspended magnet, magnetic separators, and metal detectors, to ensure that sized
coal, free of foreign material is supplied. Then it is sent to Crusher House for further
crushing to 25- mm2 size. After crushing, the coal again screened for elimination of
extraneous materials, weighed and sent to boiler bunkers. Excess coal, if any, is sent to coal
yard for stacking. It then falls through a weigher into the Bowl Mill where it is pulverized.
The mill usually consists of a round metal table on which large steel rollers or balls are
positioned. The table revolves, forcing the coal under the rollers or balls which crush it. Air
is drawn from the top of the boiler house by the FD Fan and passed through the RAH, and
then send to boiler for burning of coal. PA Fan takes air from atmosphere and distributes
them into 4 parts and fed directly to Mill blowing coal along pipes to boiler furnace.
The boiler consists of a large number of tubes extending the full height of the structure
and the heat produced raises the temperature of the water circulating in them to form
superheated steam which passes to the Boiler drum. The steam is fed through the outlet
valve to the HP Turbine(High Pressure turbine) at around 540°C and 147kg/cm^[Link]
this, it is returned to the boiler and reheated before being passed through the IP & LP
Turbine(Intermediate and Low Pressure
Turbine).The water fed into boiler is DM water.
From the turbine the steam passes into Condenser to be turned back into water. This is
pumped through CEP which sends water through LPH, and
HPH for further heating and BFP then sends it to the Economizer where the temperature
is raised sufficiently for the condensate to be returned to the lower half of the steam
drum of the boiler.
The flue gases produced in boiler are used to reheat the condensate in the
Economizer and then passes through the ESP where ash is collected. Finally, they are
drawn by the ID Fan into the main flue and to the chimney.

From the boiler, a steam pipe conveys steam to the turbine through a stop valve (which can
be used to shut off steam in an emergency) and through control valves that automatically
regulate the supply of the steam to the turbine. The turbine shaft usually rotates at 3000
RPM. This speed is determined by the frequency of the electricity system and the number of
poles of machine
Cold water from feed pool is circulated through the condenser tubes and as the
steam from the turbine passes round them it is rapidly condensed into water. Water
which gets heated up in condenser by cooling steam is sent to Cooling tower and then
left into feed pool from where it can be further used.
The electricity is produced in turbo generators and is fed through terminal
connections to Generator Transformer, those steps up the voltage to 220kv(U#7&8).
From here conductors carry it to Switchyard from where it is sent for use.

Coal Handling Plant

• Objectives of Coal Handling Plant are

• Transportation and Handling of Coal.
• Arrangement for transferring of coal from coal-wagons to coal-bunker or coal
stock yard.
• Supply of Crushed coal to bunker
 CHP: Overview

Coal Mine Track Paddle Magnetic

Hopper Feeder Separator

Crusher House
Coal
Bunker
Stack Yard

Fig: The coal Conveyor Belt & CHP of Unit # 7 & 8

At power plant, coal is unloaded in track hoppers of length 200-250m normally.

Paddle Feeder is used to feed coal to conveyor belt from track hopper.
After separation of magnetic particles from coal, it is carried to the Crusher House
through conveyor belts and after that it is either stored at Stack Yard to be carried to
coal bunker for burning.

WATER TREATMENT PLANT

Raw water supply

Raw water received at the thermal power plant is passed through Water Treatment Plant
to separate suspended impurities and dissolved gases including organic substance and
then through Demineralised Plant to separate soluble impurities.

Deaeration
In this process, the raw water is sprayed over cascade aerator in which water flows
downwards over many steps in the form of thin waterfalls. Cascading increases surface
area water to facilitate easy separation of dissolved undesirable gases (like hydrogen
sulphide, ammonia, volatile organic compound etc.) or to help in oxygenation of mainly
ferrous ions in presence of atmospheric oxygen to ferric ions.

Coagulation
Coagulation takes place in clariflocculator. Coagulant destabilises suspended solids and
agglomerates them into heavier floc, which is separated out through sedimentation.
Prime chemical used for coagulation is alum.

Filteration
Filters remove coarse suspended matter and remaining floc or sludge after coagulation
and also reduce the chlorine demand of the water.

Chlorination
Neutral organic matter is very heterogeneous i.e. it contains many classes of high
molecular weight organic compounds. Humic substances constitute a major portion of
the dissolved organic carbon from surface waters. They are complex mixtures of
organic compounds with relatively unknown structures and chemical composition

Demineralised Water Plant

In De-mineralised Plant, the filter water of Water Treatment Plant is passed through
the pressure sand filter (PSF) to reduce turbidity and then through activated charcoal
filter (ACF) to adsorb the residual chlorine and iron in filter water
 BOILER
Boiler is device for generating steam for power processing or heating purposes. Boiler
is designed to transmit heat from an external combustion source contained within the
boiler itself. Boilers may be classified on the basis of any of the following
characteristics:
Use: The characteristics of the boiler vary according to the nature of service performed.
Customarily Boilers are called either stationary or mobile.
Pressure: To provide safety control over construction features, all boilers must be
constructed in accordance with the Boiler Codes which differentiates boilers as per their
characteristics.
Materials: Selection of construction materials is controlled by boiler code material
specifications.
Size: Rating core for boilers standardize the size and ratings of boilers based on heating
surfaces. The same is verified by performance tests.
Tube Contents: In addition, shell type of boiler, there are 2 general steel boiler
classifications, the fire tube and water tube boilers.
Firing: The boiler may be a fired or unfired pressure vessel.
Heat Source: The heat may be derived from
a) The combustion of fuel
b) The hot gases of other chemical reactions
c) The utilization of nuclear energy
Fuel: Boilers are often designated with respect to the fuel burned.
Fluid: The general concept of a boiler is that of a vessel that is to generate a steam.
Circulation:The majority operate with natural circulation. Some utilize positive
circulation in which the operative fluid may be forced ‘once through’ or controlled
with partial circulation.
Furnace position: The boiler is an external combustion device in that the combustion
takes place outside the region of boiling water. The relative location of the furnace to
the boiler is indicated by the description of the furnace as being internally or externally
fired. The furnace is internally fired if the furnace region is completely surrounded by
water cooled surfaces. The furnace is externally fired if the furnace is auxiliary to the
boiler.

Boiler Accessories
Boiler furnace: A boiler furnace is that space under or adjacent to a boiler in which
fuel is burned and from which the combustion products pass into the boiler proper. It
provides a chamber in which the combustion reaction can be isolated and confined so
that the reaction can be isolated and confined so that the reaction remains a controlled
force. It provides support or enclosure for the firing equipment’s.
Boiler Drum: The function of steam drum is to separate the water from the steam
generated in the furnace walls and to reduce the resultant solid contents of the steam to
below the prescribed limit of 1ppm. The drum is located on the upper front of the boiler.
Economizer: The purpose of the economizer is to preheat the boiler feed water before
it is introduced into the steel drum by recovering the heat from the fuel gases leaving
the boiler. The economizer in the boiler rear gas passes below the rear horizontal super
heater.
Super Heater: There are 3 stages of super heater besides the side walls and extended
side walls. The first stage consists of horizontal super heater of convection mixed flow
type with upper and lower banks located above economizer assembly in the rear pass.
The 2nd stage super heater consists of pendant platen which is of radiant parallel flow
type. The 3rd stage super heater pendant spaced is of convection parallel flow type the
outlet temperature and pressure of the steam coming out form the super heater is 540
ºC and 147 kg/cm2.
Preheater:The function of preheater is to reheat the steam coming out from high
pressure turbine to a temperature of 540 ºC. Burners: there are total 24 pulverized coal
burners for corner fired C.E. type boilers and 12 oil burners provided each in between
2 pulverized fuel burners.
Igniters: There are 12 side Eddy plate oil/ H.E.A igniters per boiler. The atomizing air
for igniters is taken from plant air compressor at 7 kg/cm2. There are 2 igniter air fans
supply air for combustion of igniter oil. Mainly 2 types of igniters are used:-
eddy plate igniter , high energy arc type igniter.
 Boiler Feed Pump
BFP is multistage centrifugal pump meant to supply boiler with required feed water at
high pressure.
It comprises of impeller and diffuser arrangement to simultaneously increase velocity
and pressure.

TECHNICAL SPECIFICATION OF BFP

Unit 7 & 8
• No. of BFP -3 (2 running + 1 Standby)
• 3
CAPACITY (M /HR) - 380
• DELIVERY HEAD - 2320 M
• PERMISSIBLE +VE SUC. HEAD - 10kg/cm2
• FEED WATER TEMP.(0C) - 165
• NO. OF PUMP STAGES - 11
• 0
PUMP I/L TEMP.( C) MAX. - 165
• NOMINAL SPEED (RPM) - 2890
• Power - 6.6 MW
• 3
FLOW RATE THROUGH R/C( M /HR) - 130

STEAM TURBINE
A steam turbine is a mechanical device that extracts thermal energy from pressurized
steam, and converts it into useful mechanical work.
Three turbines, HP turbine, IP turbine and LP turbine, are synchronized together with a
common shaft connected to the generator. HP and IP turbines have single flow unit
while LP turbine has double flow unit so as to accommodate the increase in volume of
steam due to the drop in pressure.
High pressure steam enters the HP turbine at 147 Kg/cm2 and 540o C temperature. The
steam leaves the HP turbine at a pressure of 30 Kg/cm2 and is carried to re-heaters
which heats it up to a temperature of 540o C while maintaining its pressure at 30 Kg/cm2.
This steam is carried to IP turbine after which it is directly send to LP turbine. The
steam reaches to LP turbine at a pressure of 1.5 Kg/cm2.
The steam is also carried from turbines to LP heaters and HP heaters to heat the water
entering the boiler. After loosing its pressure and temperature steam is taken to the
condenser.
Power output is proportional to the steam pressure drop in the turbine
 Turbine Auxiliaries
Regenerative Heaters
• The regenerative heaters are used to heat the Condensate from the condenser to the
boiler inlet.
• This makes the mean temperature of heat addition in boiler high resulting in high
efficiency.
• The heating is done by steam bled from different stages of HP, IP and LP turbines.
• The heaters are non mixing type.
• The drip formed is cascaded to lower heaters in the line and finally to deaerator( for HP
heaters) and condenser ( for LP heaters)
• The heaters before BFP are called Low Pressure Heaters (LPH) and those after BFP are
called High pressure heaters (HPH).
• The Deaerator is the only mixing type heater in the power plant.
• In some design drip pumps are used to pump the drip from LPHs to the main condensate
line.
 Ejector
• The ejector is used to remove air from the condenser steam space so that proper cooling
and thus vacuum can be maintained.
• The ejector uses steam and expands it in the nozzles of the ejector to create vacuum
which sucks the air steam mixture. This is then expanded in the diffuser and pressure is
increased.
• A 3 stage ejector is used to eject the air from the condenser to the atmosphere.
• Some designs use vacuum pumps to suck air.

COOLING WATER CYCLE:

Condenser:

Condenser is basically a heat exchanger which condenses a steam and converted into
water. After expansion of steam in LP turbine it enters in the condenser. In condenser
there are many water tubes are provided to condensate the steam.

• It is provided to expand the working steam below the atmospheric pressure.

• It also converts the steam water mixture to water by condensation.
This water can be easily transported (than the steam) to the boiler.
• There are tubes which carry the clarified water.
• On the shell side the steam condenses.
• These tubes can be made of alloys of Cu & Ni, SS.
• During overhauling the tubes are cleaned by special bullets which are triggered by
pressurized water. This cleaning removes deposits from the tube inner surface.
• After overhauling it is important to detect the leaking tubes by carrying out “FLOOD
TEST”.

Cooling Tower
The hot water from condenser outlet reaches to cooling tower. Cooling towers are
evaporative coolers to remove the heat of water so that water can be recirculating &
can be reused. This heat of water is ejected to the atmosphere by evaporation. There
are two types of cooling towers, Natural Cooling & Forced cooling .In DVC-CTPS
modern type Forced cooling towers are used in which cooling fan (suction) is required
to remove the heat of water.

Turbo-GENERATOR
This Turbo generator is basically a Synchronous Alternator. The stator houses the armature
windings and the rotor houses the field windings. D.C. voltage is applied to the field windings
through the slip rings or brushless excitation system. When the rotor is rotated the lines of
magnetic flux cut through the stator windings. This induces an e.m.f. in the stator windings.
The rotor is rotated at 3000 rpm by the turbines and a frequency of 50 Hz is required,
by the formula f=NP/2, we see that it is a 2 pole machine. The generator used in DVC has YY
configuration in the stator. This is done to distribute the amount of generated current among
the two circuits in order to increase the amount of output current by reducing the branch
impedance since voltage induced remains constant.
Generator Components
1. Rotor: The rotor is a cast steel ingot and it is further forged and machined. The rotor is to
be designed very accurately as it has to work on speeds such as 3000 rpm. Also a fairly high
current is to be carried by the rotor windings to generate the necessary magnetic field.

2. Rotor winding: Silver bearing copper is used for the winding with mica as the insulation
between conductors. A mechanically strong insulator such as micanite is used for lining the
slots. When rotating at high speeds centrifugal force tries to lift the windings out of the slots,
so they are screwed to the rotor body. The two ends of the windings are connected to slip
rings, usually made of forged steel.

3. Stator core: The stator is the heaviest load to be transported. The major part of this load is
stator core. This comprises of an inner frame and outer frame. The outer frame is a rigid
fabricated structure of welded steel plates, within this shell is a fixed cage of girder built
circular and axial ribs. The ribs divide the yoke into compartments. The inner cage is usually
fixed to the yoke by an arrangement of springs to dampen the double frequency vibrations.
The stator core is built from a large number of punching’s or sections on thin steel plates.

4. Stator windings: Each stator conductor must be capable of carrying the rated current
without overheating. The insulation must be sufficient to prevent leakage currents flowing
between the phases to earth. Windings for the stator are made up from copper strips wound
with insulated tape which is impregnated
with varnish, dried under vacuum and hot pressed to form a solid insulation bar. These bars
are then placed in stator slots and held in with wedges to form the complete winding. The
end turns are rigidly braced and packed with blocks to withstand the heavy forces.

Generator Cooling
Rotor Cooling System: The rotor is cooled by means of gap pick up cooling, wherein the
hydrogen gas in the air gap is sucked through the scoops on the rotor wedges and is directed
to flow along the ventilating canals milled on the sides of the rotor coil, to the bottom of the
slot where it takes a turn and comes out on the similar canal milled on the other side of the
rotor coil to the hot zone of the rotor. Due to rotation of the rotor, a positive suction as well
as discharge is created due to which a certain quantity of gas flows and cools the rotor.
The conductors used in the rotor windings are hollow which is done to have internal cooling
of the rotor.
Hydrogen Cooling System: Hydrogen is used as a cooling medium due to its high heat
carrying capacity and low density. But it can also form an explosive, or escape out of the
generator casing which may result into many catastrophic results. So the pressure of H2
should be maintained properly. The filling in and purging of H2 is to be done safely without
bringing in contact with air. To fill H2 inside generator first CO2 is filled through generator
and then H2 is passed since H2 has no reaction with CO2 and while taking H2 out of
generator first H2 is taken out then CO2 is passed through generator and then air is allowed
to enter. To stop the hydrogen from escaping the generator casing oil sealing is done. The
shaft of the rotor has many blades connected at the end of the shaft. Each of the blades
rotates in the slot engraved in the generator casing. Now these slots are filled with oil up to a
certain level, so that the ends of the blades rotate in an oil medium which is separated among
them. So when the H2 tries to escape and comes near the end of the shaft it passes through
the blade that is through the oil in the slot, due to which a major part of it gets obstructed and
the left out gas proceeds to the next slot. Now at the end there is almost no or negligible
amount of gas leakage.

Stator Cooling System: The stator is cooled by distillate which is fed from one end of the
machine by Teflon tube and flows through the upper bar and returns back through the lower
bar of another slot. The stator winding is cooled in this system by circulating DM water
through hollow conductors. The DM water should be at 40°C. As it is a closed loop the water
that comes out of the generator is again cooled and demineralized. Water passes through
lower bars along the length to the other end returns through the upper bars of another slot
and drain into drain header.

Ratings of Turbo Generator

For Unit # 7 & 8

Rated Voltage: 16.5 kV

Rated Power: 250 MW
Rated KVA : 250 MVA
Stator Current: 10219 A
Rotor Current: 2395 A
Frequency: 50 Hz
Connection: YY
Power Factor: 0.85 LAG
Coolant Used: Hydrogen
Rated H2 Pressure: 3KgF/cm2
Operational Duty: S1
Class of Insulation: F
Manufacturer: BHEL
 TRANSFORMER
The transformers used in a power station have its sides abbreviated as Low Voltage (LV) and
High Voltage (HV) rather than primary and secondary.

Major transformers in a power station:

1. Generator transformer:
The generator is connected to this transformer by means of isolated bus duct. This
transformer is used to step up the generating voltage of 15.75 KV or 21 KV (depending on
the generator) to grid voltage normally 220 kV. This transformer is generally provided with
OFAF cooling.

2. Unit Auxiliary Transformer (UAT):

The UAT draws its input from the main bus duct connecting generator to the generator
transformer. It is used for the working of large devices such as boilers, heavy motors etc. The
total kVA capacity of UAT required can be determined by assuming 0.85 power factor and
0.9 efficiency for total auxiliary motor load. For large units, it has become necessary to use
more than one auxiliary transformer. It uses the generated 16.5kV to c overt into 6.6 [Link]
maximum short circuit currents on auxiliary bus should be limited with in the maximum
switch gear rating available. The maximum permissible voltage dip while starting the largest
single auxiliary motor, usually boiler feed pump, shall remain within acceptable limits.

3. Station Transformer:
The station transformer is used to feed the power to the auxiliaries during the start up.
This transformer normally rated for the initial auxiliary load requirements of unit. In
physical cases this load is of order of 60% of the load at full generating capacity. It is
also provided with on load tap changer to cater to the fluctuating voltage of the grid.

4. Auto Transformer(AT):
It connects 220KV substation to 132 KV substation & Vice-Versa.

Cooling of Transformer

Heat is produced in the winding due to the current flowing in the conductors (I2R) and in the
core on account of eddy currents and hysteresis losses. In small dry type transformer heat is
dissipated directly to the atmosphere. In oil immersed transformer heat is dissipated by
Thermo Siphon Action.

The purpose of using oil is:-

a. Cooling: Provides a better cooling and helps in exchanging heat
b. Insulation: A non conductor of electricity so good insulator.

The oil used is such that its flash point is pretty high so that it doesn’t have any possibility to
catch fire.
There various types of cooling:-
i. AN – Air Natural
ii. ON – Oil Natural
iii. AF – Air forced
iv. OF – Oil forced
v. ONAF – Oil natural Air forced
vi. OFAN - Oil forced Air natural
vii. OFAF – Oil forced Air forced

The oil serves as the medium for transferring the heat produced inside the transformer
to the outside transformer. Thermo siphon action refers to the circulating currents set
up in a liquid because of temperature difference between one part of the container and
other.
When oil gets heated up the oil with greater temp, goes to the upper side of the transformer.
Now if it is Oil natural it is cooled in it as it is whereas in Oil Forced a radiator is being
constructed and a pump is being attached to it to pull the oil from the upper part of the
transformer.
Now this oil in the chamber gets cooled either by direct heat exchanging through the
atmosphere which is called Air Natural or by forced air draft cooling by a radiator with many
electric fans which are automatically switched on and off depending upon the loading of
transformer which is known as Air Forced cooling. As the oil gets cooled it becomes heavier
and sinks to the bottom.

GENERATOR TRANSFORMERS 2 Nos. (one for each unit)

Rating: 250MVA
No load voltage : 220/sqrt(3)/16.5kV
Current : 10291/656.08
Cooling : OFAF
Vector group: Ynd11*
Phase : 3
Freq.: 50HZ
Manufacturer : BHEL
*after 3 phase bank formation.

UNIT AUXILIARY 4 Nos. (Two for each unit)

TRANSFORMERS (UAT)
Rating : 32 MVA
Transformation ratio: 16.5v 12% / 6.9-0-6.9
Vector group: d/ d-d 11-11

STATION SERVICE 2 Nos. (One for each unit)

TRANSFORMER (SST)
Rating : 66 MVA
Transformation ratio: 220kV 12% / 6.9-0-6.9 kV
Vector group: Yo/ d-d 11-11
Make: BHEL
 SWITCHYARD
It is a switching station which has the following credits:
(i) Main link between Generating plant and Transmission system, which has a large
influence on the security of the supply.
(ii) Step-up and/or Step-down the voltage levels depending upon the Network Node.
(iii) Switching ON/OFF Reactive Power Control devices, which has effect on Quality of
power.

Switchyard Equipments

Transformers:
Transformer transforms the voltage levels from higher to lower level or vice versa,
keeping the power constant. Auto transformer (AT) are used to connect 400KV
switchyard to 132KV switchyard.

Circuit breakers:
Circuit breakers makes or automatically breaks the electrical circuits under loaded condition.

Isolators:
Opens or closes the electrical circuits under No-load conditions.

Instrument transformers :
Instrument transformers are used for stepping-down the electrical parameter (Voltage or
Current) to a lower and safe value for Metering and Protection logics.
CTs are single phase oil immersed [Link] current is generally 1A, but also 5A in
certain cases.
The CVTS are used at 220KV & above. For lower voltages electromagnetic type
transformers are mostly used. The secondary voltage is 110/sqrt(3).
Earth switch:
Earth switches are device which are normally used to earth a particular system to avoid
accident, which may happen due to induction on account of live adjoining circuits. These
don’t handle any appreciable current at all.

Lightning arrestors: station type “lightening arresters” are provided at the terminals of the
transformers for protection against lightening or any surges developing in the system, the
practice is also to install lightening arresters at the incoming terminals of the line. Shielding
of substation from direct lightening stroke is provided through earth wires located at
structures
‘peaks’. Recently masts are also used for the purpose of shielding substation.

Overhead earth wire:

It protects the O/H transmission line from Lightning strokes.
Now a days OPGW are used for communication purpose also.

Switchgear

Switchgear is one which makes or breaks an electric circuit. The equipment’s which
normally fall in this category are:-
• Isolators
• Switching Isolators
• Circuit Breakers
• Load Break Switches
• Earth Switches

Isolators can break an electric circuit when the circuit is to be switched on no-load only.
These are normally used in various circuits for the purpose of isolating a certain portion
when required for maintenance etc.

Switching isolators are capable of

1. Interrupting transformer magnetized currents
2. Interrupting line charging current and
3. Load transfer switching
Its main application is in connection with transformer feeders as the unit makes it possible to
switch out one transformer while the other is still on load.

Circuit Breakers can break or make the circuit on load and even on faults. The equipment is
most important and is heavy duty equipment mainly utilized for protection of the various
circuits and operation at load. Normally circuit breakers are installed accompanied by
isolators.

Load break switches are those interrupting devices which can make or break circuits at 8
times the rated current. These are normally installed on the same circuit or on the circuits
which are backed up by circuit breakers.
Earth switches are devices which are normally used to earth a particular system to
avoid accident, which may happen due to induction on account of live adjoin circuits.
These do not handle any appreciable current at all.

Communication
Types of communication in TPP

1. VSAT
2. PLCC
3. VHF
4. VLDC & Operational Communication
5. Inter Communication

Modes of Communication

1. Simplex – Only Transmit and Receive

2. Half-Duplex – Either Transmit or Receive at a time
3. Fully-Duplex – Transmit and Receive at the same time

PLCC (Power line Carrier Communication)

Conventionally B-Phase wire of the transmission line is used for communication purpose
DVC-CTPS

Wave Trap:
It is the device used to separate out the high frequency communication signal from the low
frequency power signal. Wave traps are installed at the exit point of the switchyard.
It consists of an inductor in series with the transmission line and a capacitor after the
inductor in parallel. The series inductor bypasses the low frequency power signal and blocks
the high frequency communication signal to enter the switchyard, whereas the parallel
capacitor bypasses the high frequency communication signal and blocks the low frequency
power signal.
This kind of arrangement ensures the safety of both the communication as well as power
generation system
Now a days OPGW (Optical Ground Wire) are used in place of wave trap system and
is more efficient and reliable.
 ASH HANDLING PLANT
A large quantity of ash is, produced in steam power plants using coal.
Ash produced in about 10 to 20% of the total coal burnt in the furnace. Handling of ash is a
problem because ash coming out of the furnace is too hot, it is dusty and irritating to handle
and is accompanied by some poisonous gases. It is desirable to quench the ash before
handling due to following reasons:
1. Quenching reduces the temperature of ash.
2. It reduces the corrosive action of ash.
3. Ash forms clinkers by fusing in large lumps and by quenching clinkers will disintegrate.
4. Quenching reduces the dust accompanying the ash.
Fly ash is collected with an electrostatic precipitator (ESP)
 ELECTROSTATIC PRECIPATATOR
It is a device which captures the dust particles from the flue gas thereby reducing the
chimney emission. Precipitators function by electrostatically charging the dust
particles in the gas stream. The charged particles are then attracted to and deposited
on plates or other collection devices. When enough dust has accumulated, the
collectors are shaken to dislodge the dust, causing it to fall with the force of gravity to
hoppers below. The dust is then removed by a conveyor system for disposal or
recycling.

Electrostatic precipitation removes particles from the exhaust gas stream of Boiler
combustion process. Six activities typically take place:

Ionization - Charging of particles

Migration - Transporting the charged particles to the collecting surfaces

Collection - Precipitation of the charged particles onto the collecting surfaces

Charge Dissipation - Neutralizing the charged particles on the collecting surfaces

Particle Dislodging - Removing the particles from the collecting surface to the hopper

Particle Removal - Conveying the particles from the hopper to a disposal point
 MOTOR
A 3-φ induction motor, stator connected 2 or 3φ supply produces a rotating magnetic field.
Speed of rotation is proportional to the main frequency and inversely proportional to the no.
of pair of poles. Stator can have single layer windings with each coil side occupying one
stator slot. Many types of stator windings are encountered. 2 most common types are: -
1. Single Layer winding – Each winding is distributed over a number of stator slots.
2. Double Layer winding – Each stator slot contains sides of two separate coils.

Definition: Motor form the single largest prime mover found in power stations and are used
for multipurpose.

Induction Motor
There are various types and sizes of motors used in the power stations. These are used
for various purposes as prime movers. Apart from the simple motor used in different
areas, these HT motors used in the various heavy-duty equipment’s. These are FD, ID,
PA fans, boiler feed pumps, CW pumps, etc. These motors have certain special
features like cooling, auto starting, inter locks and control. These are generally
squirrel cage motors. The rotor never rotates at the synchronous speed. Off load, the
induction motor has poor efficiency and power factor. On load we get an efficiency of
85% and 0.8 power factor.
Synchronous Motor
These are motors which always run at synchronous speed and speed of rotation depends
upon the pair of poles. Synchronous motors do not start on their own they need an external
exciting system which gives it an initial rotation. Generally, an induction motor is used for
this purpose. As the load increases, load angle increases and power drawn from the supply
increases. With an excessive load, the rotor pulls out of synchronism. When operating at
synchronous speed the power factor can be changed by varying the degree of excitation.
The motors are generally started using DOL (Direct Online Starters)

Rating of Various motors attached to pumps and fans:

1) BFP-4000 kW, 6.6kV, 405A, p.f.-0.89, 2979 RPM. This is the biggest motor of power
plant consuming a huge power and rotating at speed greater than that of turbine.

2) CEP-250 kW, 6.6kV,26A,1480 RPM

3) Mill motors-340 kW,6.6kV,41 A,991 RPM

4) CWP-2000 kW, 6.6 kV, 250 A, p.f.-0.74, [Link] is also a big motor which needs
to pump large quantity of water thereby reducing its speed.

5) ID fan-1250 kW, 6.6 kV, 147 A, 597 RPM

6) PA fan-420 kW, 6.6 kV, 45.9 A, 1490 RPM
7) FD fan-1st speed - 550 kW, 6.6 kV, 73 A, 597 RPM
2nd speed -1000kW, 6.6 kV, 114 A, 746 RPM

SAFETY
Control and elimination of Hazard to attain an acceptable level of Risk is termed as Safety

Safety = Hazard Elimination + Risk Management

Common Hazards

Direct contact with electricity (Electric Shocks)

Boiler fires and explosions
Contact with hazardous chemicals

Outcomes Of Accidents

Negative Positive
▪ Injuries ▪ Reoccurrence can be prevented
▪ Losses ▪ Improvement in design of
▪ Death equipments
Accident prevention Strategies

Engineering Methods
Administrative controls
Personal Protective Equipments ( A Second Line of Defence )
Training & Education ( Imparting Morale & Knowledge )

Prevention systems for Fire hazards

( At DVC – CTPS )

Fire extinguishers
Co2 flooding system
Water spray system
Nitrogen flooding
Gas flooding system

Steps of Risk Assessment

1. Identify the Hazard

2. Decide who might be harmed and how
3. Evaluate the risks & decide on precautions
4. Record risk ratings & identify the existing risk controls
5. Review your assessment & update if necessary

INFERENCE
Industrial training being an integral part of engineering curriculum provides not only easier
understanding but also helps acquaint an individual with technologies. It exposes an
individual to practical aspect of all things which differ considerably from theoretical models.
During my training, I gained a lot of practical knowledge which otherwise could have been
exclusive to me. The practical exposure here will pay rich dividends to me, when I will set
my foot as an Engineer.
The training at DVC-RTPS was altogether an exotic experience, since work, culture and
mutual cooperation was excellent here. Moreover, fruitful result of adherence to quality
control awareness of safety and employees were fare which is much evident here.
 References

➢ IN HOUSE MAGAZINES AND MANUALS OF DVC

➢ PICTURES TAKEN FROM

• DVC-RTPS UNIT#7 &8

• [Link]/DVC-RTPS

➢ WEBSITES VISITED :

• [Link]/DVC-RTPS

• [Link]

• [Link]/DVC-RTPS