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Generator Auxiliary Control System using Ethernet

Description Circuit Diagram Circuit Diagram 2 TI Launchpad Promotion

TABLE OF CONTENTS:

1. Generator Auxiliary Control System

using Ethernet
2. Existing System

3. Proposed System

4. Microcontroller

5. SCADA

6. Ethernet

7. TCP / IP Protocol Stack

Contributor: P. Srinivasan, Tanjore, India

1. INTRODUCTION

Neyveli lignite corporation limited was registered as a company on 14th November 1956.The

mining operations in Mines were formally inaugurated on 20th may 1957 by our prime minister

Mr. Pandit Jawaharlal Nehru.

Neyveli lignite corporation limited (NLC) consist of Mine I, Mine II & Mine IA. It also consists of

Thermal Power Station I , Thermal Power Station IA and Thermal Power Station II. We are doing
our project in Thermal Power Station II.
F&D SPEAKERS F&D F210X 2.1
A510 2.1 MULTIMEDIA
Rs. 2,532.00 Rs. 1,989.00
(details + delivery) (details + delivery)

1.1 THERMAL POWER STATION-II

TPS-II has been a major power source of power to all southern states of India. The 1470mw
capacity power station consists of 7 units of 210mw each. The power station was constructed in

2 stages in 630mw and 840mw.The rst 210mw unit was synchronized in March 1986 and the last
unit in June 1993.This power station has seen a series of technologies innovation such as

 1.1.1 SPECIAL FEATURES
Largest Thermal Power Station in Asia.

First and largest Tower type Boiler in the country (92.7mw).

First largest Boiler Management System.

124 meters natural draught cooling towers.

220 metres tall chimney for wide disposal of gases.
Distributed digital control system, data acquisition system for control and instrumentation.

The power generated from TPS-II after meeting the needs of the MINE-II is shared by the
Southern States viz, TamilNadu, Kerala, Karnataka, A.P and union territory of Pondicherry.

1.2 POWER ALLOCATION

Andhra Pradesh - 19%(277mw)

Karnataka - 14%(199mw)
Kerala - 10%(155mw)

TamilNadu - 30%
(441mw)
Pondicherry - 5% (80mw)
N.O ` - 7%(100mw)
UN allocated share - 15%(220mw).

1.3 DESIGN
The second thermal power station consists of seven numbers of 210mw units and since having

installed capacity of 1470mw.Units 1,2&3 were constructed in the 1st stage followed by the stage
units 4,5,6&7.Lignite for the station is supplied from Mine-II having an annual capacity of 10.5
million times. The First stage units are fully of foreign origin .

Generators are of M/S ercole marselli; italys supply. The second stage units are fully of M/S

BHELLS supply even though the boilers are of M/S EVT Germanys design and generators are of
Russian design. 901401 million unites of electricity can be generated per annum from this power
station at 70 % annual plant load factor(PLF)but the actual production gures in recent years are

much higher.

Fig no

1.3: Single line diagram

2. ELECRICAL
SYSTEMS
Stage-I generators are
hydrogen cooled. The
generating voltage is
15kV, which is stepped up to 230kV. In stage-II, the generator has a stator water-cooling system.

Rotor and other parts are hydrogen cooled. The generating voltage is 15.75kV, which is stepped up
to 400kV. Static excitation is also employed. Two hydrogen plants supply hydrogen for the
generators. On 230kV, there are 10 feeders, on 400kV side there are 5 feeders. A switchyard
control room regulated the power ow. Each unit has a control room with elaborate protection,
interlocks, control circuits and instruments. Data acquisition system is employed in Stage-I

whereas Distributed Digital Control is available for Stage-II units.



2.1 210MW GENERATOR SPECIFICATIONS

Active power = 210 MW

MVA rating = 247 MVA

Reactive power = 130 MVAR

Power factor = 0.85 lagging
Voltage = 15 kV
Current = 9507A
Frequency = 50Hz

Speed = 3000 rpm

Cooling system = hydrogen cooled

H2 pressure = 3.12 kg/cm2

Excitation voltage = 340V

Excitation current = 2854A.

In electricity generation, an electrical generator is a device that converts mechanical energy to

electrical energy, generally using electromagnetic induction. A generator forces electric charges to
move through an external electrical circuit, but it does not create electricity or charge, which is
already present in the wire of its winding.

3. COOLING PROCESS
The generator losses are dissipated as heat through stator and rotor bodies. An efcient,
ventilating system is needed to keep the temperature of the windings resulting due to various

losses below certain limits depending upon insulation. Also the demand for increased output from
a single generator necessitated improved methods of cooling to keep the size of the generator

with in the reasonable limits, to minimize losses and to improve efciency of generator.

The primary cooling medium is air or hydrogen, which in turn is passed through a water cooled

heat exchanger (gas cooler). Building of air cooled turbo generators above 50 MW rating
presented serious ventilation difculties, not only in circulating requisite quantity of air through the

machine, but also because the high fan power required to circulate the air. The cooling system

shall also ensure that no excessive hot spots occur at windings/core. As the single largest loss in
the generator is the windage loss, the air must be replaced with a lighter gas. Hydrogen has a

great advantage that its density at atmosphere pressure is only 1/14th of that of air. So, windage
loss can be reduced in the same ratio. Because of many other properties like specic heat,

density, thermal conductivity etc., hydrogen is widely used as coolant in large turbo-alternators.

3.1 ADVANTAGES OF HYDROGEN COOLING

1. Windage and ventilating losses are reduced due to the low gas density.
 2. An increased output per unit volume of active material because of the high thermal
conductivity and high heat transfer co-efcient of hydrogen.

3. The life of the insulation on the stator winding is increased because of the absence of
oxygen, moisture and the corona discharge.

4. The reduction of windage noise, dirt and moisture because of lesser density of gas and
closed recirculation.

5. Because of the hydrogen atmosphere inside the generator, the chances of re are reduced as
hydrogen cannot support combustion or oxidization.

3.1.1 PRODUCTION OF HYDROGEN

Hydrogen is the most abundant chemical element, constituting roughly 75% of the universe's
elemental mass. Hydrogen may be produced from water by electrolysis at substantially greater

cost than production from natural gas. The electrolysis of water is a simple method of producing

hydrogen. A low voltage current is run through the water, and gaseous oxygen forms at the anode
while gaseous hydrogen forms at the cathode. Typically the cathode is made from platinum or

another inert metal when producing hydrogen for storage. If, however, the gas is to be burnt on
site, oxygen is desirable to assist the combustion, and so both electrodes would be made from

inert metals.

3.1.2 APPLICATIONS OF HYDROGEN

H2 is used as the rotor coolant in electrical generators at power stations, because

it has the highest thermal conductivity of any gas.

Since H2 is lighter than air, having a little more than 1/15th of the density of air, it

was once widely used as a lifting gas in balloon.

In more recent applications, hydrogen is used pure or mixed with nitrogen

(sometimes called forming gas) as a tracer gas for minute leak detections and
airships.

Applications can be found in the automotive, chemical, power generation, aerospace,

and telecommunication industries.

The chances of re are reduced as hydrogen cannot support combustion or

oxidization.

3.2 HYDROGEN GAS SYSTEM

Hydrogen treatment plant supplies hydrogen to the generator for cooling purpose. The hydrogen

gas is transferred in cylinders at a pressure of 150 kg/cm2. The pressure is reduced to 3.5

kg/cm2 and supplied at the top portion of the generator. The generator gets heated up due to

various losses and the huge amount of current owing through the stator. Hydrogen absorbs the
heat generated and in turn, it gets heated up.

The hydrogen gas is now termed as the HOT GAS. The air blower (fan) collects the hot gas and

forces it towards the cooler (g 2.1).

Fig no 3.2 : Hydrogen gas system

Two vertical coolers are being placed at the turbine end. The cooler consists of many tubes

through which chill water ows. The hot gas passes through the coolers and gets cooled. Once
the gas is cooled, it is being termed as COLD GAS. The chill water, owing in the tubes, inside
 the cooler,
is being

controlled

by two
valves (70%

valve and
30% valve).

The 30%

valve is an
auto valve

which is
controlled

by using a

microprocessor. The 70% valve is being controlled manually.

GENERATOR AUXILIARY CONTROL SYSTEM - Program.zip

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Comments

nice article.
Submitted by abhay on Fri, 22/03/2013 - 21:42

nice article.

Reply

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