Project Report

On
Feroze Gandhi Unchahar Thermal
Power Project

Reporting Officer:

Mr MADHUR KUMAR DGM (TMD)

Submitted by:

ANSHUMAN SINGH
Mechanical engg.

FGUTPP, Unchahar
Rae Bareli (U.P.)

VIT UNIVERSITY
CHENNAI (TAMIL NADU)

Acknowledgement
I am very grateful and thankful to all those who were a part of this
project and helped me towards its smooth and efficient completion. I feel
especially thankful to Mr. MADHUR KUMAR DGM (TMD) and Mr G.P.
YADAV, to name a few for their helpful contribution and knowledge
without which my project would not be a reality.

ANSHUMAN SINGH
Mechanical Engg.
Third Year
VIT UNIVERSITY
CHENNAI (TAMIL NADU)

Contents
1.

Introduction

2.

Principle of a steam Power Plant

3.

Rankine Cycle

4.

Various Cycles in Steam Power Plant

5.

Coal Handling Plant

6.

D M Plant

7.

Coal , Water & Steam Cycle

8.

Steam Production

9.

Turbine

10.

Ash Handling Plant

11.

Electrostatic Precipitator

12.

Variable Frequency Drive

13.

Generator

14.

Generator Cooling System

15.

Switch Yard

16.

D C System

17.

Conclusion

INTRODUCTION
Electrical energy demand has been rapidly increased in India by the
seventies. This is attributed to greater industrialization and large scale
use of Electrical energy for Agricultural purpose.
The major sources of Electrical energy in India are
fossil fuels (coal, oil and gases) and water. The relative contribution
of thermal plants is 62% ~ 82%. It has been increased during some
resent years only. The central government has set up many thermal
power projects. National Thermal Power Corporation (NTPC) was set
up in 1975 for planning execution of large pithead power station and
associated transmission networks. NTPC has set up six super thermal
power stations having total capacity of 20000 MW at the following
places:

Singrauli
(U.P.)
Korba
(M.P.)
Ramagundem (A.P.)
Farakka
(W.B.)
Vindhyanchal (M.P.)
Rihand
(U.P.)
It has total installed capacity of 39174 MW and has the goal to reach
the capacity of 12 GW. Today it has projects at the following places:-

NORTHERN REGION STATION

Singrauli ------------------ (5*200+2*500) MW

Rihand ---------------------(4*500) MW
Unchahar -------------------(5*210)MW
Tanda-------------------------(4*110)MW

SOUTHERN REGION STATION

Ramgundam ------------------(3*200+4*500)MW
Kayamkulam-------------------(2*155 GT+ 1*120 ST) MW

WESTERN REGION STATION

Korba -----------------------------(3*200+3*500)MW
Vindhyanchal---------------------(6*210+5*500)MW
Kawas ------------------------------(4*106 GT +2*105 ST)MW

EASTERN REGION STATION

Farraka--------------------------(3*200+2*500)MW
Kahalgaon-----------------------(4*210+1*500)MW
Talcher-----------------------------(4*60+2*110)MW
Talcher-Kanhia--------------------(6*500)MW

NATIONAL CAPITAL REGION STATION

Dadri coal -------------------------(4*210)MW

Auta ---------------------------------(3*88 GT+ 1*149 ST)MW
Auriya -------------------------------(4*110 GT +2*106 ST)MW
Faridabad-----------------------------(2*143 GT +1*144 ST) MW

FIROZ GANDHI UNCHAHAR THERMAL

POWER PROJECT (FGUTPP)
foundation stone was laid by Late, Prime Minister Mrs. Indira
Gandhi in June 1981.
First two units of 210MW were commissioned on 21stNovember,
1988 and 22ndMarch, 1989 by U.P. Rajya Vidyut Utpadan Nigam.
FGUTPP was handed over by U.P. Rajya Vidyut Utpadan Nigam to
NTPC in 13th February, 1992.
After take over of FGUTPP from UPRVUN to NTPC, unit-3 & unit-4
were commissioned on 27th January, 1999 and 22nd October, 1999.
Station has bagged many awards. NTPC Unchahar stood 9th best
power station in the country in terms of PLF in the year 1999-2000
and 2000-2001.
Now third stage (unit-5 & unit-6) is proposed to be of 1210 MW and
1490MW.

Principle of the Steam Power Plant

The working principle of a steam plant is based upon the Rankine
cycle. Generally steam is taken as the working medium due to its ability to
be stable and that its readily stable. The flow of steam in the plant can be
very easily be understood by the flow diagram of the plant. A graph plotted
between the temperature and the entropy would indicate the technical details
of the working by the Rankine cycle. The entropy of a system can be
understood as an index of degradation of energy.

PLANT FLOW DIAGRAM

MODIFIED RANKINE CYCLE

AB- Heating of feed water (i.e. sensible heat addition)

BC- Evaporation of water in boiler (i.e. latent heat addition)
CD- Superheating of steam (i.e. heat addition)
DE- Isentropic expansion of steam in HP turbine
EF- Reheating of steam in Reheaters
FH- Isentropic expansion of steam in IP and LP turbine
HA- Condensation of steam in the condenser
Point G-Demarcation between superheated and wet steam

In order to achieve the high efficiency, the following points should be kept
in mind:
The value of useful heat or the temperature of useful heat should
be high.

 The value of rejected heat or the heat of rejection temperature

should be low.
To increase the boiler efficiency (plant efficiency) following methods are
used:
Super heating
Reheating
Feed water heating
Efficiency of Rankine cycle without superheating = 27.01%
Efficiency of Rankine cycle with superheating = 44.23%
Efficiency of Rankine cycle with reheating = 46.09%
Efficiency of Rankine cycle with feed water heating = 51.4%

Various Paths or Cycles in power plant

1. Coal Cycle :
Railway wagon power house wagon tipplercoal hopper
CHP conveyor belt crusher house conveyor belt coal
stockyard or RC bunker RC feeder pulverised mill furnace
2. Feed water cycle :
DE aerator boiler feed pump HP heater economiser boiler
drum
3. Condensate water cycle :
Condenser hot well condensate extraction pump gland steam
cooler LP heater DE aerator
4. Steam cycle :
Boiler drum LT SH platen SH final SH HP turbine
Reheater IP turbine LP turbine condenser
5. Air Path :
P.A. fan air heater & cold P.A. fan mill furnace
F.D. fan
6. Flue gas path :Furnace Reheater economiser air preheater
E.S.P. I.D. fan chimney atmosphere

Coal Handling Plant

The fuel used in the thermal power plants in the boiler furnace is coal.
Coal undergoes various processes like separation, crushing, etc and is then
finally moved to the furnace in the form of pulverised coal.
Coal: it is a mixture of organic chemicals and mineral materials produced by
natural process of growth and decay. The chemical properties of any coal
depend upon the proportions of different chemicals components present in it.
There are four types of coal:
1. Peat
2. Lignite
3. Bituminous Coal
4. Anthracite
In the plant we use bituminous coal which is one of the most important
varieties of coal, being soft and widely used as fuel. Its approximate
composition is
C = 85%
H = 5%
O2 = 7%
The rest is comprised of sulphur, phosphorus, sodium and other minerals in
traces. Basically the coal used in the plant contains carbon, some volatile
material, moisture and ash. The ash content in the coal is around 30- 40 %.

Properties of Coal
1. Calorific value: the heat evolved when unit amount of coal is burned.
2. Gross calorific value: the heat evolved when all the products of
combustion are cooled to the atmospheric temperature.
3. Net calorific value: it is the value obtained when GCV is subtracted
by sensible and latent heat of water in the products of combustion.
4. Grindablity: it is the ease with which the coal can be ground to fine
sizes. It is measured on the hard grove scale. Coal used here has a
Grindablity index of 55.

Coal analysis
It is done in two ways:
1. Proximate analysis: it gives the behaviour of coal when heated.
2. Ultimate analysis: it tells the elementary composition of coal. it is
useful in determining the air required for combustion and in finding
the weight of combustion products.

Coal Transportation & Handling

Railways are the most commonly used method of coal transportation.
Coal is transported in wagons of capacity 50-56 tonnes. The wagon is
emptied with the use of wagon tippler or track hopper. With the help of
wagon tippler one wagon at a time can be emptied while with the help of
track hopper have the rack can be emptied at a time

Various Equipments Involved

Marshalling Yard: it consist of railway tracks provided to receive the
loaded trains, to unload them and to put them back in formation without
interference between loaded and empty racks.
Wagon Tippler: this consist of tippler structure that supports the wagon
during tippling; the hoisting machinery which transmits the motor power
from the driving motor to the tippler structure. It also consists of balance
weight which reduces the load on the motor by balancing a portion of
weight of the structure. To prevent the wagon from falling the tippler is
provided with stopper to fix the angle the tippler rotates the wagon.
Beetle charger: this can be used for placing wagons on to the tippler
cradle without the use of locomotive. Hence it avoids unnecessary
investment.
Crusher: these are used to break the received coal from 250mm size to
about 20mm size. The crusher consists of fast moving rotor with a
number of hammers mounted on rods. The coal gets crushed by free
impact as it comes in the path of hammers.
Stacker Reclaimer: it is used for stacking and reclaiming coal from the
stockyard. The maximum design capacity is 450 metric tonnes per hour.
The stacker reclaimer mainly consist of :
o Bucket wheel

o Boom conveyor
While the belt conveyor carrying the coal for the stockyard is in the
same
Direction but the direction of the boom conveyor with respect to the
stacking and reclaiming is in opposite direction.
The stacker reclaimer does the following three functions:
1. travelling (movement in forward and reverse direction)#
2. luffing (up and down movement)
3. slewing (left and right movement)
The stacker reclaimer also has two cable reeling drums in which the
reeling action is done by electrical medium and the unreeling is done
mechanically. Great care has to be taken during this operation since any
loop hole can lead to accidental results. During the stocking operation the
coal from the crusher house is diverted towards the stockyard conveyor at
a transfer point. The above conveyor discharges coal to the boom
conveyor through a discharge chute. The boom conveyor running in the
forward direction creates coal stacks
During reclaiming, coal from the stockyard falls on the boom
conveyor with the help of bucket wheel and the boom conveyor during
this period rotates in the reverse direction. The coal from the central
chute falls on the conveyor belts used for transferring the coal from the
stockyard

Advantages:
1. It can operate at full load capacity in bad weather.
2. It is productive at all times as no return journey is to be performed.
The only drawback is that it is expensive.
Magnetic separator: this is an electromagnet placed above t he
conveyor to attract magnetic materials and to remove them. Over this
magnet there is a conveyor to transfer these materials to chute
provided for dumping at ground level, hence continuous removal is
possible..
Plough feeders: the plough feeder is normally installed under hoppers
for unloading the coal.

 Vibrating feeders: it is used for throwing the coal onto the

underground conveyor belt from where coal goes to the bunker.
Belt conveyor: this is used for the movement of coal from one place to
another. It is made up of nylon fabric with duck weight. For
increasing the holding capacity of belts they are toughened during
movement.

Forward conveyor

Return conveyor

Coal cycle in CHP (stage-I)

The coal cycle in CHP in completed under the following steps:
1. The coal is unloaded from wagon tippler and then through
conveyor 1A, 1B goes to transfer point-1.
2. Through conveyor 2A, 2B it goes through Cross Belt Suspended
Magnet to remove metallic impurities of type ferrous present in the
coal.
3. Then the coal whose present size is 200mm goes to the Primary
Crusher House. Here by a rotary breaker the coal is crushed to size
of -150mm. By the centrifugal action of the breaker stones and
other impurities which are not crushable by the breaker are
extracted. If the coal is to be stocked then it goes to the primary
stockyard or it goes to the metal detector. This metal detector
detects both ferrous and non-ferrous impurities.
4. Through conveyor 3A, 3B it goes to the Secondary Crusher House.
Here Rotary Granular crusher is used which has hammers attached
to crush the coal. The coal size produced by this crusher is -20mm.
if coal at this stage needs to be stocked then it goes to secondary
stockyard else it is send to stacker reclaimer from where it goes to
the bunkers in the main plant.

Ratings of Equipments used in CHP

Conveyor:
Capacity:
stage-I 800 tonnes/hr
Speed:
2.3 m/s
Width:
1000 mm
Thickness:
20 mm
Raise of inclination: 12 to 18
Troughing angle:
stage-I 20deg

stage-II 1000 tonnes/hr

stage-II 35deg

Wagon Tippler:
Slip ring induction motor 3, 6.6KV, 71KW, with electromagnetic brakes
Primary Crusher:
Induction motor 3, 6.6KV, 175KW
Secondary Crusher:
Stage-I
Number of crusher: 2
Type of motor: induction motor 3 750KW, 6.6KV
Stage-II
Number of crusher: 4
Type of motor: 3 induction motor 450KW, 6.6KV
Stacker Reclaimer (stage-II)
For travelling: 6 induction motors (7.5KW, 415V ac) with brakes.
For luffing: a hydraulic system which is valve operated.
For slewing: 2 dc-shunt motor connected in series.
Boom conveyor:
Stage-I: 37KW, 415 V
Stage-II: 75KW, 415V
Bucket wheel:
Stage-I: 55KW, 415V
Stage-II: 75KW, 415V

Differences between stage I & II CHP

Stage-I
Relay logic was used
Wagon tippler and track
hopper were added
Conveyor capacity:800
tonnes/hr
Two secondary crushers
6 paddle feeders which are
hydraulic
Cross belt magnetic
separator used

Stage-II
Programmable logic control
circuitry is used
Manual unloading track hopper
was added
Conveyor capacity: 1000
tonnes/hr
4 secondary crushers of higher
capacity
4 paddle feeders operated
through reduction gear
Inline magnetic separator used

Conveyor protection
1. Pull chord: for man and machine safety this protection technique is
provided. It is a chord that runs parallel to the conveyor and in case of
emergency it can be pulled as a result of which the conveyor would stop.
2. Belt sways: the sideways movement of the conveyor belt can be quite
troublesome and lead to damaging the whole system. When the belt
movement is away from the prescribed zone then after a certain length
this protection would come into action leading to tripping of the
conveyor motor. Belt swaying may also be the result of eccentric loading.
3. Zero speed switches: this protection comes into action when the speed of
the conveyor becomes very less than the rated or normal speed no matter
due to any reason. Reason for activation of this protection might be that
the belt might break of the motor may fail etc.
4. Linear heat sensing cable: this protection is for any type of heat related
procedures. If by any means the temperature of the conveyor belt
increases beyond a certain limit then this protection comes into action. In
this protection a special temperature sensing type wire runs through the
periphery of the conveyor structure

De mineral (D M) Plant
Introduction
Water is required in plant for many purposes like for formation of steam, for
removal of ash, for safety during fire etc. But the water required for
formation of steam should be perfectly devoid of minerals because if it
would be present with the steam then it will strike the blades of turbine and
due to being in high pressure it produces scars or holes on the turbine blades.

Purification of water
Water is purified in DM plant through a chain of processes as under:1. Carbon filter -:Water taken from river is first sent to the carbon filter
for the removal of carbon content in the water.
2. Strong acid cation exchanger-: After passing through the carbon
filter water is sent to the strong acid cation exchanger which is filled with
the concentrated HCL. The acid produces anions which get combined
with the cations present in the water.
3. Strong base anion exchanger-:After passing though the two
chambers of strong acid cation exchanger water is sent to the strong base
anion exchanger which is filled with the concentrated NaOH. The base
produces cations which get combined with the anions present in the
water.
4. Mixed bed exchanger -: At last water is sent to the chamber of mixed
bed exchanger where the remaining ions are removed.

Coal, Water & Steam Cycle

COAL CYCLE

C.H.P Plant Bunker R.C Feeder pulverize mill Boiler section

R.C. Feeder -: it is induction motor driven device, which determine the
Quantity of coal enter in to pulverize mill
Pulverize mill: - Pulverization means exposing large surface area to the
action of oxygen. Two types of mill are used in the plant.
Ball mill:- A ball mill operates normally under suction. A large drum partly
filled with steel balls, is used in this mill. The drum is rotated slowly while
coal is fed in to it. The ball pulverizes the coal by crushing. This type of mill
is used in stage -1.
Contact mill:- This mill uses impact principle. All the grinding elements
and the primary air fan is mounted on a single shaft. The flow of air carries
coal to the primary stage where it is reduced to a fine granular state by
impact with a series of hammers. This type of mill is used in stage-2.

WATER CYCLE
D.M. Plant Hot Well C.E.P. Pump Low Pressure heater
1,2,3Derater Boiler Feed pump High pressure Heater 5,6
Feed Regulating station Economizer Boiler Drum.
DERATER:. Feed storage tank of water.
. To produce sufficient pressure before feeding to B.F.D.
. Filter the harmful chemicals.
FEED REGULATING STATION:. Control the quantity of water in to boiler drum.
ECONOMISER:. Flue gases coming out of the boilers carry lot of heat. An economizer
extracts a part of this heat from the flue gases and uses it for heat the feed
water.
DRAFTS SYSTEM:. In forced draft system the fan is installed near the base of the boiler
furnace. This fan forces air through the furnace, economizer, air preheater
and chimney.
. In an induced draft system, the fan is installed near the base of Chimney.

STEAM CYCLE
Boiler drums Ring Header Boiler Drum (Steam chamber)
Super Heater H.P. Turbine Reheater I. P. Turbine
L.P. Turbine.
BOILER DRUM :Boiler drum consist two chamber water chambers, steam chamber. Before
entering in super heater the steam is going in to boiler drum, where the
boiler drum filtered the moisture and stored in to water chamber.
SUPER HEATER:The function of super heater is to remove the last traces of moisture from the
saturated steam leaving the water tube boiler. The temperature is approx
5300 c.
TURBINE:Steam turbine converts the heat energy in to mechanical energy and drives
on initial and final heat content of the steam. Turbine having number of
stage in which the pressure drops takes place.

Steam Production
After all the coal is fed to the rc feeder from rc bunker where the coal comes
from the coal handling plant whose size is -20mm. then this coal goes to the
mill for further crushing. The coal is further crushed and takes the form of
talcum powder. This coal is hence called pulverised coal. The coal mills are
HT induction motors. Coal feeders are used to transport the coal from RC
bunker to the mill. The advantages of using pulverised coal are that it is
easily combustible and pulverisation increases the surface area for
combustion and hence the thermal efficiency increases.
In stage-I 4 mills are used which feed 4 elevations out of 6 which run
simultaneously.
In stage-II 2 mills are used which feed 4 elevations out of 6 in the
furnace. The mills employed in stage-I are Bowl type mills. In this type of
mill coal is fed from the bunker to the mill by means of a feeder. The coal
falls on to the mill grinding table and is carried under the grinding rolls
which reduce the coal into pulverised form.

The mills employed in stage-II are ball & tube mills. They operate at a
speed of 17-20 rev/min and in modern power plants they are used as
pressure type mills. The mill drum carrying the ball rotates on the
antifriction bearings. Raw coal is fed inside the drum and it gets crushed.
The ball charge and coal is taken to a certain height and then allowed to fall
down. The coarser particles from both mills are returned by the classifier for
further grinding. From the mills the pulverised coal is then taken to the
furnace by the medium of air which is supplied by the Primary air fan.
Primary air fans are also of 2 types; hot air and cold air type. Hot air fan
contains blast of hot air which removes the moisture from the pulverised
coal and the cold air is simply used for carrying the coal. Primary air fan
motor is a HT motor.
The pulverised coal finally reaches the furnace. It is a primary part of
the boiler where the chemical energy available in the fuel is converted into
thermal energy by combustion. Furnace is designed for efficient and
complete combustion. The pressure inside the furnace is maintained at -5mm
to 10mm of water column. The air inside the furnace is not sufficient for full
coal burning hence Forced Draught fans are employed for blasting air inside
the furnace at very high pressure. Then to start the firing some oil is also
sprinkled by means of oil igniters.
The method which has been adapted at FGUTPP is the Tangential
Firing of Corner Firing. Here the burners are set at each corner of the
furnace and directed to strike the outside of an imaginary circle in the
furnace which is called the Fire Ball. Since the streams of fuel strike each
other, extremely good mixing is obtained.

Water

tube Boiler Schematic Layout

Furnace is placed at the bottom of the most important part of the

thermal plant where steam is generated. The boiler used at FGUTPP is the
water tube boiler type in which, water circulates in tubes surrounded by fire.
Hence it takes up heat and gets converted into steam. The steam then rises

up and gets collected inside the boiler drum. The boiler is made up of carbon
steel. The temperature of steam that comes out of the boiler is around 530
deg Celsius and its pressure is 120kg/cm2. The type of boiler can be further
elaborated as natural circulation, dry bottom, and tangential fired, radiant
heat type with direct fired pulverised coal system.
Once the steam is produced in the boiler, it gets collected inside the
boiler drum. Boiler drum is a special type of cylindrical drum like structure
which contains a mixture of water and steam. Steam being lighter gets
collected at the top portion and beneath it we have the water. It is very
important to maintain a safe level of water in the drum since we have two
main types of constraints in this regard. If the steam produced and collected
is more then it can lead to a blast in the boiler drum else tiny droplets of
water can enter the turbine. Hence in order to keep a check we measure the
level by hydrastep. Hydra step is a phenomenon based on the difference in
the conductivities of water and steam.
Since there is great pressure and temperature at the boiler great care
should be taken while going to the site and maintenance.
Since coal is burning in the furnace and then we have water tubes of
the boiler inside hence constant burning of coal produces ash which gets
collected on the water tubes and the start working as insulation, hence its
necessary to blow this soot hence for this purpose we use Soot Blowers.
Soot blowers are basically pipe like structures that go inside the
furnace and the boiler for efficient onload cleaning. Cleaning is done by the
superheated steam which is tapped from the superheater for the purpose of
soot blowing. The pressure is reduced to 31kg/cm2 at 330 deg Celsius by
means of reducing valve. We mainly have three types of soot blowers:
1. long retraceable soot blower
2. wall blower
3. air reheater
Before sending this steam to the turbine, the steam is again superheated
and then its temperature is around 580deg Celsius. This increases the
efficiency since the temperature is the measure of energy hence higher
temperature higher is the energy. Hence, during the phenomenon of
superheating the steam which is dry and saturated, is being heated and hence
the temperature of steam again rises.
First the steam from boiler drum enters the low temperature super heater
(LTSH). After LTSH steam enters the platen super heater and then finally to
a high temperature super heater. The steam which is now produced goes to
the HP turbine.

Turbine
The superheated steam after coming out of the superheater goes to the
turbine. A turbine is a form of an engine running on steam, which requires a
source of high grade energy and a source of low grade energy. When the
fluid flows through the turbine a part of the energy content is continuously
extracted and continuously converted into useful mechanical work.
The main advantage of using a steam turbine rather than a prime mover is
that the steam in a turbine can be expanded down to a lower back pressure,
thereby making available a greater heat drop and a larger amount of this heat
drop can be converted into useful mechanical work owing to higher
efficiency of the turbine. Therefore a turbine is suitable for driving a
generator.
Turbines are of two types:
1. Impulse Turbine
2. Reaction Turbine
However another form called impulse-reaction turbine is also used which
provide benefits of both types. The impulse-reaction turbine is used here at
FGUTPP.
Here three stages of turbine are used:
HP turbine (high pressure)
IP turbine (intermediate pressure)
LP turbine (low pressure)

Steam Flow in the Turbine

A View of the in house Steam Turbine

The steam flow in the turbine takes place as follows; the steam from
the super heater first goes to the HP turbine where it does work and loses its
temperature. The steam from HP turbine is the fed to the reheater where its
temperature is increased pressure remains the same as that from the outlet
from HP turbine. The steam from the reheater is then fed to the IP turbine
and then finally to the LP turbine. The LP turbine is connected to the
generator and the mechanical output from the turbine is used to drive it.

Ash handling plant

The ash produced in the boiler is transported to the ash dump area by means
of ash handling system. It contains bottom ash system, fly ash system and
ash slurry system.
Bottom Ash-: the bottom ash is collected in water troughs employed below
bottom ash hoppers. The ash is continuously transported onto the respective
clinker grinders which reduce lump sizes to fineness. The crushed ash from
the clinker grinder falls into the hopper and from here it is taken to the ash
slurry house.
Fly Ash-: the fly ash also gets collected into the separate hoppers where it
gets mixed with flushing water.
Ash Slurry System-: this is the main system which is responsible for
carrying away the ash slurry.
The bottom ash and the fly ash slurry of the system is sluiced upto ash slurry
pump along the channel with the aid of high pressure water jets located at
suitable intervals along the channel. The ash slurry pump house has the
following specifications. It contains 4 series with 3 pumps each to carry
water upto 6 kilometres. It has got a control room where all the controlling is
done and simultaneously monitoring is also there. The panel consist of
various relays, SF6 circuit breaker and other motor controls. These pumps
are all high tension pumps working on 6.6KV. To maintain the pressure we
also have lp seal pump and hp seal pump which are all driven by 3
induction motors

Ash slurry pump house

Ash Slurry Pumps
Number of pumps:12
Capacity: 720m3/hr
Speed: 970 rpm
Rating: 6.6KV, 35KW

LP Seal Water Pumps

Head: 65m
Capacity: 8.06 lps
Drive HP: 7KW
Speed: 1450rpm

HP Seal Water Pump

Head: 156m
Capacity: 5.56lps
Drive HP: 12.87KW
Speed: 2900rpm

Ash slurry pump arrangement

Ma, Mb, Mc: motor driving respective pumps

Pa , Pb , Pc : ash slurry pumps
The ash removing system can also be divided into types i.e., dry ash and wet
ash. Dry ash can be taken out from the hoppers through some openings and
then they are sent to cylos from where they are sent to cement industries.
Wet ash is removed as slurry by the ash slurry pumps

Electrostatic Precipitator (ESP)

The ash content in the Indian coal is of the order of 30 to 40 %. When
coal is fired in the boiler, ashes are liberated and about 80% of ash is carried
along with the flue gases. If this ash is allowed to flow in the atmosphere, it
will cause air pollution and lead to health troubles. Therefore it is necessary
to precipitate the dust from the flue gases and this work is done by the
electrostatic precipitator.
Working principle:
The principle upon which an electrostatic precipitator works is that dust
laden gases are passed into a chamber where the individual particles of dust
are given an electric charge by absorption of free ions from a high voltage
DC ionising field. Electric forces cause a stream of ions to pass from the
discharge electrodes (emitting) to the collecting electrodes and the particles
of ash in the gas are deflected out of the gas stream into the collecting
surfaces where they are retained by electrical attraction. They are removed
by an intermittent blow usually referred to as RAPPING. This causes the ash
to drop into hoppers situated below the electrodes. There are 4 steps that are
involved:
1. Ionisation of gases and charging of particles.
2. Migration of particles to respective electrodes.
3. Deposition of particles on the electrodes.
4. Dislodging of particles from the electrodes.
Description:
The ESP consist of two sets of electrodes, one in the form of helical
thin wires called emitting electrode which is connected to -70KV DC and
the collecting electrode in grounded.
The fundamental parts of ESP consist of:
1. Basing-: the precipitator casing is robustly designed and has an all
welded steel construction.
2. Hoppers-: the hoppers are of pyramidal shape. The angle between
hopper corner and the horizontal is never less than 55 deg and often more
to ensure easy dust flow. To ensure free flow dry ash into disposal system
the lower portion of hopper are provided with electrical heaters.
3. Collecting system-: the collecting system consists of electrodes which
are based on the concept of dimensional stability. They have a flat

4.

5.

6.
7.

uniform surface for uniform charge distribution. These electrodes have

larger area and are grounded, hence have zero potential.
Emitting system-: the emitting system consist of emitting or discharging
electrodes that are in the front of the helical wires for a non-uniform
distribution to enhance the rate of charging since a non-uniform field is
created.
Rapping mechanism-: the Rapping mechanism is a process which is
employed to hammer out the ash particles which get precipitated on the
respective plates. Hence in order to hammer out those particles rapping
motors are employed which hammer at the rate of 2 to 3 cycles per
minute. Various motors are employed and are called collecting rapping
motor and emitting rapping motor.
Insulators-: these are also employed for support since ESP is hung with
the help of these insulators.
Transformer Rectifier-: a transformer rectifier is employed which steps
up the voltage to 70KV and then it is rectified to -70 KV and is given to
the emitting electrode

Diagram of basic construction of ESP

Electrical scheme of ESP

The following mechanism takes place electrically:
Emitter electrode (E) creates a strong electric field near the surface
and corona discharge takes place.
Positive and negative ions are formed by this discharge.
The positive ions move towards anti positive charge line electrodes
called emitting electrodes and the negative ions towards collecting
electrodes.
During this passage ions collide with ash particles and adhere to them.
These charged particles stick on the collector curtain which is the
dislodged by the rapping motors which is collected by the hoppers.
For optimum functional efficiency of the precipitator the supply
voltage should be maintained near above the flash over level between
electrodes. This is achieved by the electronic control. The efficiency of ESP
is about 99.95%. The ESP is divided into 4 passes called A, B, C, D and has
various fields per pass.
In stage-I we have 7 fields per pass and hence the total no. of fields is
28 whereas in stage-II we have have 8 fields per pass and hence the total no.
of fields is 32.

Variable frequency drive

From the electrostatic precipitator, the flue gases are sucked. It is a
type of fan and is called Induced draft fan. It sucks the flue gases from the
ESP and then transfers them to the chimney. In stage-I an IM is employed
for this purpose but the speed control of that motor is not possible.
Sometimes the amount of flue gases coming out is small and other times it is
large but since no speed control is possible hence the flow of flue gases
become a tedious task. However in stage-II the speed control is possible
since here we have variable frequency drive. The motor which is employed
here are synchronous motor.
Using variable frequency drive voltage is compensated at low frequencies,
the torque at low speeds is improved. To obtain the voltage boost, we require
a controlled converter as well as a controlled inverter. The electrical scheme
is shown below

The above panel is a variable frequency drive panel. First the three phase
supply from transformer is fed to the controlled rectifier which the ac to dc.
The advantage of using a controlled rectifier is that the average value of the
output can be controlled by varying the firing angle. Then its output is fed to
the inverter which is a type of load commutated inverter. Before passing it to
the inverter a reactor is also employed in between this reduces the ripples.
The inverter then converts dc to ac and the ac is fed to the synchronous
motor. The speed of synchronous motor is fixed and is given by 120 f / p.
since the only thing variable in the expression is the frequency which is
directly proportional to the speed. Hence the inverter varies the frequency
and hence controls the speed of the motor. The controlled rectifier in the
circuit is used for voltage control while the load commutated inverter is used
for frequency variation

Two channel arrangement for synchronous motor

The stator of the synchronous motor is given supply
using two channels. Normally the motor works on both channels but under
some faulty conditions on any one of the channels the other channel can
continue working since the motor is required for continuous operation

Hence the
frequency is varied from 0.5 Hz to 47.5Hz. When both channels operate the
motor moves at 575rpm and when one channel is in operation the maximum
speed is 475rpm. The power and current ratings in case of both the channels
is 1414KW & 420Amp. In case only one channel is working then the power
is 635KW and current is 380Amp

Ratings of synchronous motor

Frame: IDQ 4134
KW rating: 1414KW
KVA rating: 1646
Power factor: 0.9 (lead)
Speed: 575
Stator voltage: 2 X 1200 V
Excitation voltage: 170 V dc
Insulation class: F
Phase: 2 X 3
Connection: double star
Stator amps: 2 X 396
Excitation amps: 64 dc
Degree of protection: IP54
Duty: continuous
Weight: 19,000 Kgs

Advantages of Variable Frequency Drive

1. Speed control is fine as the frequency is varied from 0.5Hz to 47.5 Hz.
2. Very low starting current as motor starts on reduced voltage.
3. Power consumption is low.
Motor life is improved

Generator
The transformation of mechanical energy into electrical energy is carried
out by the generator. The generator also called the alternator is based
upon the principle of electromagnetic induction and consist of a
stationary part called the stator and a rotatory part called rotor. The stator
houses the armature windings and the rotor houses the field windings.
The alternator is a doubly excited system and the field is excited from dc
supply whereas the output received from the alternator is ac. When the
rotor is energised the flux lines emitted by it are cut by the stator
windings which induces an emf in them given by
E = 4.44 f N
Where f frequency in Hz
field strength in webers/m2
N speed of rotor in rpm
Turbo generators run at a very high speed hence the no. of poles are
generally two and have a cylindrical rotor construction with small
diameter and long axial length.

Generator main components

The main components of a generator are the rotor and stator.
Rotor:
the electrical rotor is the most difficult part of the generator to design. It
is an electromagnet and to give it the required strength of magnetic field
a large current is required to flow through it. The rotor is a cast steel
ingot and is further forged and machined.
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. Rotor has hollow conductors
with slots to provide for circulation of the cooling gas.
Rotor balancing: the rotor must then be completely tested for
mechanical balance which means that a check is made to see if it will run
up to normal speed without vibration.
STATOR
Stator frame: it is the heaviest load to be transported. The major part is
the stator core. This comprises an inner frame and an outer frame. The
outer frame is a rigid fabricated structure of welded steel plate. In large
generator the outer casing is done in two parts.
Stator core: it is the heaviest part and is built from a large no. of thin steel
plates or punching.
Stator windings: it is of lap type and employs direct water cooled bar
type winding. The stator winding bar is made from glass lapped
elementary conductor and hollow conductors. The main insulation is
applied by means of mica tape which is wrapped and is compounded with
the help of a silicon epoxy compound.

Excitation system
The electric power generator requires direct current excited magnets for
its field systems. The excitation system must be reliable, stable in
operation and must respond quickly to excitation current requirements.
Based on the excitation systems the type of excitations can be:
Normal excitation
Brushless excitation
Normal excitation: normal dc supply is given to the field winding of the
alternator. After the rotor is excited and stator winding is given ac supply,
then magnetic locking is created. But it was found that dc excitation
could not meet the demands of large capacity turbo generators because
they employed brushes for making external contacts. The other
disadvantage of dc exciter is that commutator may be satisfactory during
steady state but during load fluctuations, there is risk of flash over at the
commutator. To correct this fault the brush less excitation was
introduced. The normal excitation system is used in stage-I whose ratings
are given below:
KW rating: 210,000
KVA rating: 247,000
Rated terminal voltage: 15.75 KV
Rated stator current: 9050 Amps
Rated power factor: 0.85 lag
Excitation current: 2000 Amps
Excitation voltage: 310 V
Rated speed: 3000 rpm
Rated frequency: 50 Hz
Connection: double star
Rotor cooling hydrogen pressure: 3.5 Kg/cm2
Hydrogen purity: 98 %
Stator cooling water pressure: 3.5 Kg/cm2
No. of poles: 2
Insulation class: B
Rotor type: cylindrical type

Brush less excitation system:

this system gained favour because it was possible to use 2 or 4 pole
revolving field type machine possessing all the robust associated with the
generator. Commutator and dc brush gear were eliminated. A pilot exciter is
necessary part of this system. This is a permanent magnet generator. The
following scheme is employed

This is present in stage-II where an arrangement is there in which a

pilot exciter drives the main exciter whose output first passes through the
automatic voltage regulator which is then fed to the rotating diode wheel
which converts the ac to dc and then it is coupled to the rotor of the main
generator which gets dc excitation. In this arrangement no brushes are
used and hence no sparking occurs therefore no wear and tear takes place,
hence the maintenance cost is reduced.

Ratings of turbo generator stage- II

KW rating: 210,000
KVA rating: 247,000
Rated terminal voltage: 15.75 KV
Rated stator current: 9054 Amps
Rated power factor: 0.85 lag
Excitation current: 2080 Amps
Excitation voltage: 270 V
Rated speed: 3000 rpm
Rated frequency: 50 Hz
Connection: double star
Insulation class: F
Gas pressure: 8 bars

Ratings of permanent magnet generator

KW rating: 5
KVA rating: 8
Terminal voltage: 220 V
Speed: 3000 rpm
Coolant: air
Connection type: double star
Rated current: 26 Amps
Phase: 3
Power factor: 0.6 lag
Insulation class: F
Frequency: 150 Hz

Generator cooling system

Turbo generator is provided with an efficient cooling system to avoid
excessive heating and consequent wear and tear of its main components
during operation. The two main systems employed for cooling are water
cooling system and hydrogen cooling system.

Hydrogen cooling system:

Hydrogen is used as a cooling medium in large capacity generator in
view of the following feature of hydrogen. When hydrogen is used as a
coolant the temperature gradient between the surface to be cooled and the
coolant is greatly reduced. This is because of the high coefficient of heat
transfer of hydrogen.
The thermal conductivity of hydrogen is 7 times that of air and hence
good heat conduction is possible. While using hydrogen it eliminates
oxygen in the chamber and hence prevents the formation corrosive acids
therefore lengthens the life of insulation. As hydrogen is a non-supporter
of combustion hence risk of fire is eliminated. The density of hydrogen is
1/14th times of air hence circulation is also easier.
The cooling system mainly comprises of a gas control stand, a driver,
hydrogen control panel, gas purity measuring instrument and an
indicating instrument, valves and the sealing system. A great care should
be taken so that no oxygen enters the cooling system because hydrogen
forms an explosive mixture with air. The purity of hydrogen be
maintained as high as 98%.to produce hydrogen in such large quantities a
separate plant called the hydrogen plant is also maintained.

Water cooling system:

Turbo generators require water cooling arrangement. The stator
winding is cooled by circulation of demineralised water through hollow
conductors. The system is designed to maintain a constant rate of cooling
water flow to the stator winding at a nominal temperature of 40 deg
Celsius.

Generator sealing system: seals are employs to prevent leakage of

hydrogen from the stator at the point of rotor exit.

Cooling specifications of turbo generators at FGUTPP

Stage-I:
water as well as hydrogen cooling is present in stage-I turbo generators
with following specifications:
Rotor cooling
Hydrogen gas pressure: 3.5 Kg/cm2
Purity: 98%
Stator cooling
Water pressure: 3.5 Kg/cm2
Rate of flow of water: 130 m3/hr

Stage-II:
only hydrogen cooling is used for both stator and rotor cooling.
Rotor cooling
Hydrogen gas pressure: 3.5 Kg/cm2
Purity: 98%
Stator cooling
Hydrogen gas pressure: 2.0 Kg/cm2
Purity: 98%

Switch yard
If we see to the electrical side of a thermal power station, the first thing
that will come to our mind is the switchyard. The main components here
apart from the transformers
comprise what is known as the
switchgear. If we talk in simple
language, switchgear is one
which makes or breaks a circuit.
This definition straight away
does not attract much curiosity
nor does it show the enormous
linking required in designing a
switchgear. Numerous problems
are encountered in erection,
testing and commissioning of the
switchgear
and
various
precautions are to be taken for
A view of the Switch Yard
proper operation maintenance.
The main components of
switchyard are:
Transformers
Generator transformer
Unit auxiliary transformer
Station transformer
Lighting arrestor
Isolators
Current transformers
Circuit breakers
Earth switches
Capacitated voltage transformers
Wave traps
Using all of the above equipments after the generation stage i.e., after the
generation has generated an output voltage of 15.75KV all these equipments
are employed for safe and economic self consumption and transmission.

Hence before this power is fed or transmitted to the other cities some
precautionary measures are taken.

Transformers
The transformer is a device that transfers electrical energy from one
electrical circuit to another through the medium of magnetic field and
without the change of frequency. It is an electromagnetic energy
conversion device, since the energy received by the primary is first
converted to magnetic and is then reconverted to electrical energy in the
secondary. Thus these windings are not connected electrically but
coupled magnetically. Its efficiency is in the range of 97 to 98 %.
TYPES OF TRANSFORMERS
1.

GENERATOR TRANSFORMER:This is a step up transformer. This transformer gets its

primary supply from generator and its secondary supplies the switchyard
from where it is transmitted to grid. This transformer is oil cooled. The
primary of this transformer is connected in star. The secondary is connected
in delta. These are four in number.
2.

STATION TRANSFORMER:This transformer has almost the same rating as the

generator transformer. Its primary is connected in delta and secondary in
star. It is a step down transformer. These are four in number.
3.

UNIT AUXILLARY TRANSFORMER:It is a step down transformer .The primary receives from
generator and secondary supplies a 6.6 KV bus. This is oil cooled. These are
8 in number.
4.

NEUTRAL GROUNDED TRANSFORMER:This transformer is connected with supply coming out of

UAT in stage 2. This is used to ground to excess voltage, if occurs in the
secondary of UAT in spite of rated voltage.

Transformer accessories

Conservator: with the variation of temperature there is a

corresponding variation in the volume of oil due to expansion and
contraction of oil caused by the temperature change. To account for this, an
expansion vessel called the conservator is connected to the outside
atmosphere through a dehydrating breather to keep the air in the conservator
dry. An oil gauge shows the level of oil in the conservator.
Breather: it is provided to prevent the contamination of oil in the
conservator by the moisture present in the outside air entering the
conservator. The outside air is drawn into the conservator every
time the transformer cools down which results in the contraction of
the volume occupied by the oil in the conservator. The breather
contains a desiccator usually Silica gel which has the property of
absorbing moisture from the air. After sometime silica gel gets
saturated and then it changes it colour from purple to pink
indicating that it has become saturated and hence needs to be
replaced or regenerated.
Relief vent: In case of severe internal fault in the transformer, the
pressure may be built to a very high level which may result in the
explosion in the tank. Hence to avoid such condition a relief vent is
provided with a bakelite diaphragm which breaks beyond certain
pressure and releases the pressure.
Bushings: they consist of concentric porcelain discs which are
used for insulation and bringing out the terminals of the windings
from the tank.
Bucholz relay: this is a protection scheme for the transformer to
protect of against anticipated faults. It is applicable to the oil
immersed transformer and depends on the fact that transformer
breakdowns are always preceded by violent generation of gas
which might occur due to sparking or arcing. It consist of two
mercury relayed switches one for a danger alarm and the second
for tripping the transformer.
Temperature indicators: transformers are provided with two
temperature indicators that indicate the temperature of the winding
and that of the oil in the transformer for an oil filled transformer.
The temperature indicators are also protective in nature whereby
the first create an alarm and then tripp the respective transformer in

case the temperature of the respective parts rises beyond a certain

value.
Tap changers: these are also provided and are mounted on the
transformer. In case some kind of load fluctuations the taps can be
changed or adjusted as per the need. There are two types of tap
changers On load tap changer and Off load tap changer.

Cooling of transformers
Heat is produced in the transformers due to the current flowing in the
conductors of the windings and on account of the eddy current in the core
and also because of the hysteresis loss. In small dry type transformers the
heat is directly dissipated to the atmosphere. In oil immersed systems oil
serves as the medium for transferring the heat produced. Because of the
difference in the temperatures of the parts of the transformers circulating
currents are set. On account of these circulating currents hot oil is moved to
the cooler region namely the heat exchanger and the cooler oil is forced
towards the hot region. The heat exchangers generally consist of radiators
with fins which might be provided with forced or natural type air circulation
for removal of heat.
The oil in oil immersed transformers may also be of forced or natural
circulation type. The oil used for cooling is silicone oil or a mixture of
naphthalene and paraffin. When forced oil circulation is used then pumps are
used for the circulation of the oil. The oil forced air forced type cooling is
used in large transformers of very high KVA rating.

Major transformers used in the plant

Generator transformer: the generator is connected is connected to this
transformer by means of isolated bus ducts. It is used to step up the
generated voltage from 15.75KV to 220KV for the purpose of transmission.
Though high voltage transmission definitely requires better insulation but it
also has the following advantages requires less conductor material and less
transmission losses hence higher efficiency. The transformer is generally
ofaf type cooled and provides off load tap changing on the HV side. It has an
elaborate cooling system consisting of oil pumps and cooling fans. At
FGUTPP there are four generator transformers (GT). GT-I & GT-II
comprise stage-I while GT-III & GT-IV comprise stage-II. The oil used in
transformers of stage-I is mineral oil which is a mixture of naphthalene and
paraffin while in stage-II we use silicone oil.

SPECIFICATIONS:-

GENERATOR TRANSFORMER (GT-1 & GT-2):KV

MVA
Phase
Hz
Connection
Type of cooling
Rated HV & IV (MVA)
Rated LV (MVA)
No load voltage HV (KVA)
No load voltage IV (KVA)
No load voltage LV (KVA)
Line current HV (Amps)
Line current IV (Amps)
Line current LV (Amps)
Temp rise oil (0 C)
Temp rise winding (0 C)

: 15.75/242
: 250
:3
: 50
: Y d 11
: OFAF/ ONAF / ONAN
: 250/150/100
: 250/150/100
: 242
: ----: 15.75
: 597.14/358.29/238.86
: ------: 9175.15/5505.09/3670.66
:50 0C
: 60/55/55 0C

POTENTITAL TRANSFORMER
Type of cooling
KVA
Phase
Hz
No load voltage HV (Volts)
No load voltage LV (Volts)
Line current HV (Amps)
Line current LV (Amps)
Temp rise oil (0 C)
Temp rise winding (0 C)

: ONAN
: 100
:3
: 50
: 6600
: 433
: 87.53
: 133.5
:50 0C
: 55 0C

NEUTRAL GROUNDED TRANSFORMER

Type of cooling
KVA
Phase
Hz
No load voltage HV (Volts)
No load voltage LV (Volts)
Line current HV (Amps)
Line current LV (Amps)
Temp rise oil (0 C)
Temp rise winding (0 C)

: ONAF /ONAN
: 1150
:3
: 50
: 6600
: 250
: 105.9
: 2655.8
:50 0C
: 55 0C

Details of generator transformer at NTPC, Unchahar

MVA
Type of cooling
Phases
No load KV (HV)
No load KV (LV)
Frequency
HV current
LV current
Vector group
Tap changer
Temperature rise oil
Temperature rise winding
Oil in litres

GT # 1,2 (BHEL)
250
OFAF
3
15.75
242
50 Hz
597A
9175A
YND11
off load
50deg Celsius
60deg Celsius
57700

GT# 3,4 (CGL)

250
OFAF
3
15.75
237
50 Hz
609A
9164A
YND11
off load
50deg Celsius
55deg Celsius
3680

Two other types of transformer namely the Unit Auxiliary transformer

and the station transformer both being used to run the station auxiliaries and
support the colonial loads. Both these transformers have natural oil
circulation and forced air circulation for their cooling.

Lighting Arrestors
These are provided to combat the effect of
over voltages and surges caused due to lighting
strokes on the transmission lines. These are
generally provided at the end near the
instrument which we want to protect. The
lightening arrestors provide an easy path to the
surge current to the ground thereby not letting
the equipments to fail. The arrestor come
generally in two types i.e., dry and oil filled
type. The dry type consists of zinc oxide filled
insulator relays while the oil filled arrestor is
similar to a high tension bushing.
A Lightening Arrestor

Isolators
These are devices used for isolation of an
instrument that is being used in the network or
currently working mesh. The isolator works by
disconnecting the device terminals from the
network thereby no current flows through the
device or the load also gets cut-off. The isolators
can be thought of switches that can either make or
break the circuit at the operators wish. The
difference of an isolator from a circuit breaker can
be realized from the fact that a circuit breakers
making or breaking of a circuit depends upon
certain predefined conditions while that of the
isolator dictates no condition.

A three phase isolator

Circuit Breaker
A circuit breaker can make or
break a
circuit depending upon its rating. If
the current flowing through the
circuit breaker in operation
exceeds the rated capacity it tripps
results in disconnection of the load.
With
the
advancement
of
technology quite many options are
available to be used a circuit
breakers. The classification of
circuit breaker is done upon the
methods used for quenching the
arc. That is when the circuit
breaker connects or disconnects the
load the current density at that
point of contact rises to high
leading to an arc which might
result to flash-over in case it is not
quenched or extinguished quickly.
The methods used for arc quenching are:
Sf6 method
Air blast method
Oil quenched
An outdoor circuit
breaker
Vacuum method
The circuit breakers used at FGUTPP are of the type of SF6 or the air blast
type.

Capacitative Voltage Transformer (cvt)

The cvt is used for line voltage measurements on loaded
conditions. The basic construction of a cvt is as follows. Each CVT
consists of a coupling capacitor (CC) which acts as a voltage driver and
an Electro Magnetic Unit (EMU) which transforms the high voltage to
standard low voltage. Depending on the system voltage the CC can be a
single or a multi stack unit. 245 kV & 420kV CVTs no normally
comprise of 2 units. The CC and the EMU are individually hermetically
sealed to ensure accurate performance and high reliability.

The main points of difference between a cvt and a potential transformer

is that in a PT full line voltage is impressed upon the transformer while
in cvt line voltage after standard reduction is applied to the transformer.

Switchyard control room

the switchyard control room or the
MCC as it is commonly known here at FGUTPP, unchahar. The control
room contains an array of relays and circuit breaker that are used for the
protection of man and machinery leading to uninterrupted and efficient
working of the plant. The MCC continuously monitors 24x7 the state of
working of the generated energy its conversion through generator
transformers, supply of power to station auxiliary bus-bars and the
distribution of generated power to various load centres. The FGUTPP caters
to the energy needs of the cities of Lucknow, Kanpur and Fatehpur through
eight transmission lines. A plan for extension of energy to Rae-Barelli is also
going on.

D.C. System
INTRODUCTION:
Dc system is generally used for control and protection
operation. Ac supply is not fully dependable. To maintain constant supply in
case of power failure we use de supply.
Dc system consists of a battery charger. These are the
mode of energy storage.
CHARGING EQUIPMENTS:The battery charging equipment comprises
of trickle charger, quick charger, battery panel, main distribution board and
switch control and signaling board.
CHARGING EQUATION:In battery Pbo2 used as positive plate and Pb
as negative plate.

Discharging process
Pbo2 + H2 + H2So4 PbSo4+2H2o (+ive)
Pb + So4 PbSo4 (- ive)
Charging process
PbSo4 +2 H2o+ So4 Pbo2+2H2So4 (+ive)
PbSo4 + H2 Pb + H2So4 (- ive)

BATTERY CHARGER
Battery charger normally operates in two modes

1. Float charging: it is a constant voltage mode and works as a trickle

charger.
2. Boost charging: it is a constant current mode and works as quick
charger.

TRICKLE CHARGER:This charger is fed from three- phase ac supply

and gives a dc- stabilized output at rated full load current. The variation of
the dc output voltage ids limited to +/-1% for 0 to 100% load variation and
simultaneously ac voltage variation of +/-10% of frequency variation of +/5% from 50 Hz. The rectification is obtained full bridge converted silicon
rectifier. Stack comprising of three SCR and three diode with the surge
suppression RC network connected across each SCR and diode.
WORKING:The circuit on phase control principle. The SCR is three
terminal device anode, cathode & gate. The main load current by anode &
cathode. The characteristic of scar is block the forward voltage when gate
current is reaches to specify can control the instant, at which the SCR goes
into conduction or triggers. Once the SCR is triggered it remains in
conduction till anode current reaches to zero or reverse voltage is applied to
it. Thus changing the instant firing can control the output voltage of Rectifier
Bridge. The potentiometers are used for adjusting the output voltage. It
senses the load current. The signal proportional to this load current to this
load current is fed to the controller. In event of load of load current
exceeding rated the full load current. This inherent protection is provided in
float charger apart from the back protection provided by HRC fuses.
The auxiliary transformers TR2-4 supply synchronizing voltages to UJT
circuit of the controller. The transformer TR-5 is power supply transformer
for controller. The diode D4 is freewheeling diode that conducts when the
load is inductive. The stored energy then flows through D4 instead of SCR.
A filter circuit comprising of choke and condenser is connected in the output
to limit the ripple contents to normal value.

QUICK CHARGER:The charger is fed from 3phase AC supply and gives a

DC stabilized output current at rated full load current. The output current of
the charger shall remain stabilized with in +/- 2% for 0 to 100% of load
variation for AC input voltage +/- 10% from 415 volts and frequency
variation +/- 5% from 50 Hz. The rectification is obtained by using a full
wave bridge connected silicon rectifier stack comprising of three SCR and
3diode with RC surge suppression network across each SCR and diode.
Solid state SCR controller adjusts the triggering angle of SCR and maintains
the current constant.

WORKING OF SYSTEM:Normally the trickle charger will float the

batteries at 2.16 volt/cell with in a stabilization of +/- 1% of floating voltage.
The trickle charge will supply trickle charging current require for the
batteries and will also de continuous load require. During this time the
trickle charger and the batteries are across the DC load terminal. When there
is a power failure the battery readily meets the various dc loads. When the
power resumes the battery has to be recharged for which the quick charger is
put on and operated in a constant current mode so that the require constant
current for recharging current can be set. It is advisable to set the constant
current from 30% to 100% of the maximum boost charging current and once
the current is set. The same shell remains constant within the 1/-20% the
higher current during the initial operation of recharging can be set after the
gassing occurs; the required lower can also be set. Whatever are the current
set they remain constant within +/-2% for boosting the battery, charger
supply to the battery is connected through a double pole dc contactor/1 of
battery panel, which can be energized by push button pb 1 of battery panel
the load is connected to battery through a single dc contactor to of battery
panel. This contactor isolates load from the battery during boost charging
of the battery, thereby preventing the excessive dc voltage (about 307)
appearing across the load sw1 one poke on/off dc switches provided to
bypass the dc contactor to if quick charger is to operated as electrical charger
as the contactor to reenergized when the charger is switched on. In the event
off the failure of ac during boost charging to maintain the continuity of
battery voltage across the load. The battery tapped diode (MR-3) provided.

SPECIFICATION OF BATTERY CHARGER:Make

Type of rectifier
Rated output current
Out put voltage range

: ICA Mumbai
: Diode rectifier
: 40 Amp.
: 24 V

BATTERY CELLS:MAKE: EXIDE MUMBAI

TYPE: LEAD ACID AUTOMATIC
UNITS

VOLTAGE

1st & 2nd

220
26
-26

AMPERE
HOURS
1400
400
150

USAGE

3rd & 4th

220
26
-26

900
2000
4000

LT switchgear &
Protection
C & I control

1st & 2nd

400
400

350
250

UPS stage 1

3rd & 4th

400

800

UPS stage 2

1st & 2nd 3rd &4th

220

400

CW & switchyard
switchgear

LT switchgear &
Protection
C & I control

Conclusion
On completion of my vocational training at Feroze Gandhi Unchahar
Thermal Power Project, Unchahar I have come to know about how the very
necessity of our lives nowadays i.e., electricity is generated. What all
processes are needed to generate and run the plant on a 24x7 basis.
NTPC Unchahar is one the plants in India to be under highest load
factor for the maximum duration of time and that to operating at highest
plant efficiencies. This plant is an example in terms of working efficiency
and management of resources to all other thermal plants in our country. The
operating plf of the NTPC as compared to the rest of country is the highest
with 87.54% the highest since its inception.
The training gave me an opportunity to clear my concepts from practical
point of view with the availability of machinery of such large rating.