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A Training Report
For Partial Fulfillment B.E Electrical Engineering from
MSIT, Janakpuri
ONNational Fertilizers limited,Panipat Unit
Presented By - Underguidance of:-
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Harshal Kumar Mr.Johnson OramB.Tech (EEE)00315004911
Acknowledgement
It is a matter of great pleasure for me
acknowledging me with profound sense of
gratitude, the invaluable help & worth
guidance rendered by my project guide Mr.
Johnson Oram .Their innumerable suggestions
which served as the material source & the
motivational force for the successfulcompletion of the training.
At last, I am thankful to all those who helped
me in any way, in achieving my goal of
successful completion of the training.
It is my pleasure to thank my fatherMr.R.K.Sonkar for his constant
encouragement and valuable advice during
the whole training period.
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Harshal Kumar
COMPANY PROFILE
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National Fertilizers Limited was established in August, 1974 to set
up two fuel oil based plants at Bathinda (Punjab) and Panipat
(Haryana). Both of them were commissioned in 1979. The Nangal
Fertilizer plant of Fertilizer Corporation of India (F.C.I) has been
merged with National Fertilizer Limited (NFL) in 1978 on thereorganization of FCI and NFL group of companies. Later, NFL
executed its gas based plant at Vijaypur (Madhya Pradesh) on HBJ
gas pipe line. Vijaypur plant had gone in commercial production
in July, 1988.
The National Fertilizers Limited is now operating three fuel based
plants located at Nangal, Bathinda and Panipat and a gas based
plant at Vijaypur. The of three fuel based plants is 900 TPD of
ammonia, 1000 TPD of urea at Nangal and 1550 TPD of urea at
Bathinda and Panipat. The capacity of gas based plant at Vijaypur
is 700 TPD of Ammonia and 400 TPD of Urea with the addition of
the gas based plant in the family of National Fertilizers Limited,
the Company now occupies the position of largest producer of
nitrogenous fertilizers in the country.
PLANTS AND CAPACITIES
CAPTIVE POWER PLANT 2X15MWH
AMMONIA PLANT 900MT/DAY
UREA PLANT 1550MT/DAY
SULPHUR RECOVERY PLANT 26.5MT/DAY
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STEAM GENERATION PLANT 3X150MT/DAY
COAL HANDLING PLANT 150&250MT/HR
DM WATER PLANT 400MT/HR
RAW WATER PLANT 2400M
Training Report
CAPTIVE POWER PLANT
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Captivepower plant has been installed to meet the total
power requirement of the plant. The turbo generators of
15MW each generate power at 11KV. Power plant can be
run in parallel and in isolation with the grid. Boiler of
210T/hr has been provided to supply stream to turbo
generators. Boiler is designed to operate on coal with
support of oil and or fully on fuel oil.
It was commissioned in 1988 with the basic purpose of
serving Panipat unit independent from HSEB grid so that
performance does not have any adverse effect.
Three main actions of plant are:-
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Steam generation plant
Turbo generator set
Transformer
STEAM GENERATION PLANT
Coal from material handling plant is taken to six bunkers
through conveyer belts. Coal from six bunkers are fed to
3 ball mills through six coal feeder for controlling the flow
of controlling the flow of coal according to the boiler
demand. Each ball mill is connected to two coal feeders
through six coal crusher.
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Major sections of SGP are:- Boiler
Super heater
Economiser
Air preheater
Electrostatic precipitator Forced shaft fans &induced shaft fans
BOILER:
Boiler in the CPP is multi relay RX type from fixed boiler.
Normal capacity of boiler is 210T/hr. Boiler is designed torun on pulverized coal supported by oil. Plant can take
full load on any type of fuel.
SUPER HEATER:
Basic function of super heater is to raise the temperature of steam above
the boiling point of water which increases the overall efficiency of the
plant. It consists of groups made up of several alloy steels such aschromium molybdenum. There are three types of super heaters namely:
radiant, convection, and separately fired. Super heaters increase the
efficiency of the steam engine, and were widely adopted. Steam which
has been superheated is logically known as superheated steam; non-
superheated steam is called saturated steam or wet steam. Super heaters
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were applied to steam locomotives in quantity from the early 20th
century, to most steam vehicles, and to stationary steam engines. This
equipment is still an integral part of power generating stations
throughout the world.
ECONOMISER:
It heats the feed water on its way to boiler. It consists of
large number of closely spaced large parallel tubes
connected by the header of the drum. Economizers are
commonly used as part of a heat recovery steam
generator in a combined cycle power plant. A common
application of economizers in steam power plants is to
capture the waste heat from boiler stack gases (flue gas)
and transfer it to the boiler feed water. This raises the
temperature of the boiler feed water thus lowering the
needed energy input, in turn reducing the firing rates to
accomplish the rated boiler output.
AIR PREHEATER:Heat absorbed from flue gas is transferred to incoming
cold air by means of continuously rotating heat transfer
elements of specially formed metal plates. An air
preheater or air heater is a general term to describe
any device designed to heat air before another process
(for example, combustion in a boiler) with the primary
objective of increasing the thermal efficiency of the
process. The purpose of the air preheater is to recover
the heat from the boiler flue gas which increases the
thermal efficiency of the boiler by reducing the useful
heat lost in the flue gas.
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ELECTROSTATIC PRECIPITATOR:
Its basic function is to free the gas from ash and
minimize the pollution. Each ESP has 10 electrodes and
18 plates. 60 KV (DC) is fed by the help of transformer
and rectifier assembly. Following is the process taking
place in the electrostatic precipitator:-
Dust laden flue gases from the boiler passes
between rows of two electrodes.
Neutral gas molecules get ionized due to theprocess of electronic field.
Positively charged ions travel towards emitting
electrodes and negatively charged ions getattached to dust particles.
Dust particles get electrically charged anddeposited on collecting electrodes.
TURBO GENERATOR SET
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Fig. Turbo generator
SPECIFICATION:
NUMBER 2
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OUTPUT 18750KVA,
15MW
RATED POWER FACTOR 0.8
RATED VOLTAGE 11000V
RATED FREQUENCY 50Hz
SPEED 3000RPM
DEGREE OF PROTECTION IP-54
INSULATION CLASS STATOR-F
ROTOR-F
TEMPRATURE STATOR-B
ROTOR-B
EXCITATION CHARACTERISTICS:
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AT NO LOAD I=276A,
V=55V
AT MAXIMUM RATED CURRENT I=580A,
V=163V
AT 125% MAX RATED CURRENT I=672A,
V=189V
EFFICIENCY AT POWER FACTOR 0.8:
100% LOAD 97.53%
75% LOAD 97.25%
50% LOAD 96.49%
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DESCRIPTION
GENERAL:
Three phase alternator set has:-
Totally enclosed self ventilated with two lateral air to
water cooling.
Horizontal shaft
Two enshield sleeve bearing with forced lubrication.
Six stator leads consisting of copper bars arranged
vertically at the bottom frame.
Rated output is given for continuous running at 50 Hz
frequency, power factor 0.8, 36C inlet temperature
of fresh cooling water and altitude above sea level
exceeding 1000m.
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STATOR CONSTRUCTION:
FRAME: The frame has parallelepiped form. It is madeof welded steel and designed to ensure the best
mechanical holding.
CORE: The core is built of low losses electrical sheetlamination insulated in accordance with insulation
process and can be clamped between two plates; thewhole is divided in to elementary stacks separated by
steel insulation which form ventilation canal for cooling of
coil.
STATOR WINDING: Stator wedge consist of identical
coils. The alternator is insulated in accordance with ourepoxy process which is an insulating system based on
mica tape with paper or Dacron support and wrapped in
multiple layer around the coil. After impregnation the
complete stator is subjected to heat treatment that
allows a compact homogeneous supervious insulated
structure to be obtained.
TERMINALS: The six main leads which consist ofcopper strip are arranged vertically at the bottom of
frame.
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SPACE HEATER: One space heater is located at thebase of stator to avoid humidity when the generator is
running.
ROTOR CONSTRUCTION:
SHAFT: Shaft end and rotor bodies are integrally forgedof high mechanical quality steel that has undergone a no.
of tests.
ROTOR WINDING: Wedge is made of cold drawnrectangular of high conductivity. The turns are framed on
mandrel and lead into the slots. The turns are stratified
glass fiber insulation.
RETAINING RING: These are fixed to the rotor body.In this way the shaft end are free to bend without
touching the retaining ring. The rings have great number
of radial holes which permits evacuation of the end
turned air.
VENTILATION: The ventilation system is designed toprovide maximum efficiency and prevents hot spots. The
art is drawn at each end of the generator by the two
helicoidally fans. After cooling the active parts of the
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machine, the air is discharged at the periphery of the
stator core and then in the coolers located on either side
of the frame.
COOLERS:The two air to water coolers are located ineither side of frame. They are formed by the nest of
round cupronickel tubes on which aluminum cooling fins
are fixed.
EXCITERDESCRIPTION: Total enclosed cooled with cold airsupplied by the main generator inverted alternators with
stationery field and rotating armature. It feeds the
generator through a rectifier mounted on shaft
connection between the rectifier bridge and main
generator field are made by hole drilled in shaft.
ROTATING ARMATURE: The lamination cut in onepiece insulated after puncturing. The slots are scrunch on
the rim that has to be keyed on the shaft. The armature
winding is installed in the open slots, secured in position
and connected to the rotatingrectifier bridge.
STATOR: The frame consist of laminated magnetic ringon which the main hole cores are bolted. The field coils
are secured on the hole cores.
RECTIFIER BRIDGE: The rectifier bridges aremounted in GRAETZ Bridge and are two types of cells.
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Each arm of the bridge uses 3 cells in parallel and
elementary rectifier bridge is protected by fuses. The size
of cells and their charge to avoid all the possibility of
overload or over voltage when the alternator is runningin following conditions:-
Three phase fault at the generator terminals.
Over voltage of the network.
None synchronized running.
GENERATOR EXCITATION:-
In both automatic and manual operation with excitation
by taping the generator must be started until a voltage of
0.1Un is reached. The stator is cut off by a voltage
threshold relay which they release the controller. In
automatic operation the generator is excited so that
rated voltage is reached immediately a variation of du
being then possible by external control.
OVERLOADING:-
When load current increases, generator speeddecreases, now reading increases.
Signal sent to control panel from where it is sent to
governing valve that in turn governs the steam inflow of the turbine.
Valve opens accordingly and steam in flowincreases.
Collaterally, now reading goes to neutral.
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DE-EXCITATION:
Whether manual or following activation of a protectiondevice, de-excitation occurs after the coupling circuit
breaker has opened following the rapid cut off of the
excitation current, the transformer/thruster set will
operate as inverter. On a de-excitation order, thruster
clock pulses are locked in the minimum position (inverter
mode) excitation contactor being then de-energized.
GENERATOR PROTECTION:
1. FREQUENCY RELAY
Solid state frequency relay with high accuracy and
stability are used:-
(a) For splitting up a grid system openingtransmission lines to prevent complete systemcollapse.
(b) For isolating small systems having their owngeneration from the main system.
(c) For the protection of generators and auxiliarywhere frequency suppression can avoid damage toturbines and auxiliary drives.
2. ACTIVE OR REACTIVE POWER RELAYS
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The WTG 7100 relays have been developed in order to
provide a static solution to the various problems of
protection requiring real measure of active power (as
well as energy flow direction supervision), a solutionoffering the following advantage:-
Unbalanced power in case of 3-wire,3-phase
networks, measured by two wattmeter method.
Great directional stability.
Active power relay is totally unaffected by current
and voltage harmonics.
Operating threshold continuously adjustable.
Low burden on current and voltage transformer.
3. OVER CURRENT PROTECTION RELAY
The ITG relay of the 7200, 7300, 7400 series provides a
complete range of phase or earth fault protection relays
inverse time extremely inverse time type with or without
instantaneous high set units. The ITG relay of the 7200,
7300, 7400 series have specifically designed or the
protection of the networks and substations against faultbetween phases or from phase to earth.
4. ALTERNATOR LOSS OF FIELD PROTECTION
RELAY
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The YTM 7111 is an admittance relay, specifically
designed for the detection by using the electrical
quantities available in its stator circuit of the loss of field
of an alternator connected to a network. To perform thisdetection, the relay is supplied from two phase circuit
and corresponding phase to phase voltage.
If the field current of alternator is interrupted either
by a short circuit or by accidental opening of the rotor
circuit, after a short period the machine will loose
synchronism. The rotor will accelerate slighter and the
alternator will operate as asynchronous generatorcontinuing to supply active power required for its
magnetization from the network to which it is connected.
The rotor motor may go above nominal due to
reactive power absorbed and low frequency currents are
induced in the damper winding and on rotor surface
causing abnormal heating of the later if asynchronous
operation continuous for too long period.
5. ROTOR EARTH FAULT RELAY
The first fault should however be first eliminated without
delay, because it allowed to remain a second fault of the
same type that would immediately put the machine out
of service and could cause very serious damage to rotor.
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The object of TTE 7015 and TTE 7017 is to detect
immediately any fault on the rotor winding of a
synchronous machine in order to give an alarm and if
required to separate the machine from network.
TRANSFORMER
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RATING
MVA 31.25/24
FREQUENCY 50 Hz
TYPE OF COOLING ONAF/ONAN
VOLTAGE AT NO LOAD
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H.V. 132KV
(STAR)
L.V. 11KV
(STAR)
T.V. 6.6KV
(DELTA)
NORMAL AMPERES AT 31.5 MVA BASE
H.V. 137.8
A
L.V. 1653.3
A
INSULATION LEVEL
H.V.
650KVP
L.V.
75KVP
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H.V.NEUTRAL
95KVP
DESCRIPTION OF TRANSFORMER
GENERAL:
The transformer is oil immersed with double rating of
31.5 MVA and 24 MVA under oil natural air forced and oil
natural air natural type of cooling respectively. The
transformer is the most convenient and economical
device for transfer of power from one voltage to another
voltage(low or high) at the same frequency. It works on
the principle of electromagnetic induction. There is
hardly any installation without a transformer. Due to thisequipment, it has been possible to transmit bulk power to
load centers from far off power houses and to various
machineries and switchgears of the power plant.
Transformers are of two types:-
STEP-UP TRANSFORMER: The transformer which
steps up the voltage at the secondary side is calledstep-up transformer.
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STEP-DOWN TRANSFORMER: The transformerwhich step down the voltage at secondary side arecalled step-down transformer.
MAIN PARTS OF POWER TRANSFORMER:
Primary winding
Secondary winding
Oil tank
Conservator
Breather
Explosion vent
Temperature gauge
Tap changer
Tubes for cooling
Transformer oil
Earth point
Primary terminals
Secondary terminals
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ACCESSORIES OF TRANSFORMER
1.OIL CONSERVATOR:
Oil conservator is a short of drum mounted on the top of
transformer. A level indicator is fixed to it, which gives
alarm at low level. Conservator is connected through a
pipe to the transformer tank containing oil. This oil
expands or contracts depending upon the heat produced
and so the oil level in conservator is left open to theatmosphere through the breather so that the extra air
may go out or come in.
2. BREATHER:
The breather is a box containing calcium chloride or
silica gel to absorb moisture that entering theconservator. Silica gel is having a property absorbing the
moisture or humidity, so it is used as breather. It is well
known fact that the insulating property of the
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transformers oil is lost if a small amount of moisture
enter in it, so dry air is passed through the breather.
3. EXPLOSION VENT:
It is also a safety device of the transformer which
protects the transformer tank from gases induced by and
any type of short circuit in the transformer. This consists
of a vertical pipe closed by diaphragm made of thin
Bakelite sheet. This diaphragm bursts or slides out in
case of abnormal pressure inside the tank.
4. TEMPRATURE INDICATOR:
It is also a protective device fitted to the transformer to
indicate temperature of transformer oil. For measuring
temperature of the oil, bulb of the vapour pressure type
thermometer is placed in the hot oil and dial of the
thermometer is mounted outside the tank. Two indicating
pointers black and red are provided. Alarm contacts are
also provided which come into action when
predetermined permissible higher temperature is
reached under abnormal operating conditions.
Temperature indicator indicates the temperature of both
i.e. the winding temperature as well as of oil
temperature.
5. BUSHINGS:
The bushing serves as supports and insulation of the bus
bars and transformer terminal. The bushing consist of
porcelain shell body, upper and lower locating washer
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used for fixing the position of bush bar and mounting
flange with the hole drilled for fixing bolt and it is
supplied with an earthing bolt.
Fig. Bushing
7. MAGNETIC OIL GAUGE:
The magnetic oil gauge supervises the level of oil in the
conservator tank. The oil level gauge is provided on the
transformer are of dial type with minimum and maximum
level marking and pointer which indicate the level of oilin the conservator. Sometimes the scale is also
graduated for oil temperature on the basis of its level
8. TAP CHANGER:
The voltage control of transmission and distributionsystem is obtained by tap changer. Tap changer are
either on load or off load tap changer. Tap changer is
fitted with transformer for adjusting secondary voltage.
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The voltage control of the range of 16% can be
achieved by tap changing transformers.
MAIN RECEIVING SUBSTATION
Total factory load is around 23.5 MW, 2 lines from HSEB
(Haryana State Electricity Board) and 2 lines from CPP
are taken to receiving towers with the help of insulator
arrangement. For the protection of switchyard, shielding
wires are also provided on receiving towers. 3
transformers step down 132KV to 11KV.
Normally 3 kinds of supply are available:
NORMAL SUPPLY :
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It is given by generator and grid. Supply levels of
132KV, 11KV, 3.3KV and 415V are available.
EMERGANCY SUPPLY :
It gets operated when there is failure of normal supply.
It is given from DG set. Generally it comes in act after
2 minutes of failure of normal supply.
CRITICAL SUPPLY :
It gives to those motor operated valves, whose non
functioning could result in blockage of pipelinescarrying poisonous gases which could lead to serious
accidents.
The protective equipments present in 132KV
switchyard are:-
LIGHTNING ARRESTOR:
They are used to protect the electrical system againstdirect lightning strokes. It conducts the high voltagesurges on the power system to the ground. Eachlightning arrestor is connected in parallel to one phasewire.
ISOLATOR:
Isolator opens a circuit under no load. The main purposeof an isolator is to isolate one portion of circuit from otherand is not intended to open while current is flowing in the
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line. They are used in both sides of the circuit breaker inorder that repair work can be performed on circuitbreaker without any damage.
CIRCUIT BREAKER:It can open a circuit under any condition i.e. under loadas well as no load conditions. It is so designed that it canbe operated manually under normal condition andautomatically under faulty condition with the help of therelay circuit. They are used to open circuit or break thecircuit. Minimum Oil Circuit Breaker (MOCB) are used inthe switchyard.
CURRENT TRANSFORMER:
They are used to measure the current flowing in thesystem. They are connected in series with each phasewire. In case of overcurrent they operate a relay which inturn disconnects all the links to faulty area.
POTENTIAL TRANSFORMER:
They are used to measure the voltage through thesystem. They are also connected in parallel to eachphase wire, in case of overvoltage they operate acorresponding relay which in turn send signal todisconnect link to the faulty area.
RATING OF SYNCHRONOUS GENERATOR AT
CPP
OUTPUT
18750KVA
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VOLTAGE
11000V
CURRENT 984A
R.P.M. 3000
P.F. 0.8
EXCITATION VOLTAGE 163V
EXCITATION CURRENT 580A
RATING OF DIFFERENT THREE PHASE
INDUCTION MOTORS INSTALLED AT CPP
1. ASH HANDLING MOTOR
VOLTAGE 3300V
KW 180
RPM 1486
PF 0.82
FREQUENCY 50 Hz
INSULATION CLASS F
2. ASH WATER PUMP-A
VOLTAGE 3300V
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KW 250
RPM 1488
FREQUNCY 50 HzP.F. 0.86
IP 55
HP 340
INSULATION CLASS B
3. ASH WATER PUMP
VOLTAGE 3300V
KW 200V
RPM 1486
CURRENT 45A
HP 270
INSULATION CLASS F
Bibliography
From Daily Dairy
From engineeringfundamentals.com
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From electric M\c by J.B Gupta.