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1. PREFACE
A very important element in curriculum of an Engineering student is the Practical Training.
I under went practical training at SURATGARH THERMAL POWER STATION from
25-05-205 to 2!-0"-205. This is a part of total #0 days training program incorporated in
the curriculum of swami $eshvanand institute of techonology%management and gramothan
for &.Tech. courses.
As I am a student of mechanical engineering% so the training at '.T.P.'. has (een particularly
(eneficial for me. I saw the various procedures% processes and e)uipment used in production
of electricity (y thermal power which were studied in (oo$s and this has helped me in (etter
understanding of power generation and various thermal concepts.
'.T.P.'. is a very large plant and it is very difficult to ac)uire complete $nowledge a(out it in
a short span. I have tried to get ac)uainted with overall plant functioning and main concepts
involved therein.
I have summari*ed all the things% which I saw + learned at '.T.P.'. in this training report.
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2. ACKNOWLEDGEMENT
It is my privilege to e,press my deep sense of gratitude towards all those who helped me
to under ta$e training in Suratgarh Super Thermal Power Staion.I would li$e to e,press my sincere than$ to prof. Alo$ mathur reader and /r% .1.
(anthiya ead /eptt. of me for giving us permission to undergo this summer training.
3ast (ut not the least% I would li$e to than$ all the other 'TA44 E&E6 of 'uratgarh
'uper Thermal Power 'taion whose timely help and support was needed for the
successful completion of the training.
And at last I want to than$ my colleagues. 7ithout their help% guidance and suggestions it
was not possi(le to produce this training report.
'A8A6 9:82E'1E0;"
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3. ABOUT PLANT
6a
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4. AN INTRODUCTION
TO
SURATGARH SUPER THERMAL POWER STATION
'uratgarh 'uper Thermal Power 'tation is owned (y 6a
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5. ELECTRICITY GENERATION
IndiaDs >F power amounting to "!57 in a total of ;">7 comes from Thermal
Power 'tation. In general it (urn fuels and use the resultant heat to raise steam which drive
the tur(o generator.
'TP' is a coal fired power station. The other raw materials are air and water. The coal%
(rought to the station (y trains %travels from the coal handling plant (y conveyor (elt to
the coal (un$ers% from where it is fed to the pulversing mills 2 which grind it as fine as face
powder. The finely powdered coal mi,ed with pre-heated% air is then (lown into the (oiler !
(y a fan called Primary Air 4an # where it (urns% with additional amount of air called
secondary air supplied (y a 4orced draft 4an #A. As the coal has (een ground so finely the
resultant ash is also a fine powder. 'ome of it (inds together to form lumps which fall intothe ash pots at the (ottom of the furnace. The water )uenched ash from the (ottom of the
furnace is conveyed to pits > for su(se)uent disposal or sale. ost of ash% still in fine
particle form is carried out of the (oiler to the Precipitators # as dust% where it is trapped
(y electrodes charged with high voltage electricity. The dust is then conveyed (y water to
disposal areas ! or to (un$ers for sale5 while the cleaned fuel gases pass on through
I./.4an to (e discharged up the 9himney ".
eanwhile the heat released from the coal has (een a(sor(ed (y many $ilometers of
tu(ing which line the (oiler walls. Inside the tu(es is the &oiler feed water which is
transformed (y the heat into steam at high pressure and temperature. The steam% super heated
in further tu(es passes to the tur(ine " where it is discharged through no**les on the tur(ine(lades. Cust as the energy of the wind turns the sails of the wind-mills% so the energy of
steam% stri$ing the (lades% ma$es the tur(ine rotate.
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6. PLANT FAMILIARIZATION
(I TURBINE !"
I#$%&')$*!
'team tur(ine is a rotating machine which 9?=E6T' EAT EE68@ ?4 'TEA T?
E9AI9A3 EE68@.
In India% steam tur(ines of different capacities% varying from 5 7 to 500 7% are
employed in the field of thermal power generation. The design% materials% au,iliary systems
etc. vary widely from each other depending on the capacity and manufacturer of the sets.
B+,*) -%*#)*-/,!The Thermal Power Plants with steam tur(ine uses 6an$ine cycle. 6an$ine cycle is a vapour
power cycle having two (asic characteristicsG
. the wor$ing fluid is a condensa(le vapour which is in li)uid phase during part of the
cycle and
2. The cycle consists of a succession of steady flow processes% with each processes
carried out in a separate component specially designed for the purpose. Each
constitute an open system% and all the components are connected in series so that as
the fluid circulates through the power plant each fluid element passes through a cycle
of mechanical and thermodynamic stages.
The tur(ine is of tandem compound design with separate P% IP and 3P cylinder. The P +
IP tur(ines are of single flow type while 3P tur(ine is of dou(le flow typeH the tur(ine iscondensing type with single reheat. It is (asically engineered on reaction principle with
throttle governing. The stages are arranged in P% IP and 3P tur(ines% driving alternating
current full capacity Tur(o generators.
TURBINE COMPONENTS
C+,*#0 &% C*#'/%,!
A casing is essentially a pressure vessel which must (e capa(le of
withstanding the ma,imum wor$ing pressure and temperature that can (e produced within it.
The wor$ing pressure aspects demand thic$er and thic$er casing and the temperature aspectsdemand thinner and thinner casings.
. .P Tur(ine 9asingG The principal parts of the P tur(ine casing are and a,ially
split inner shell% enclosing the rotor and outer shell of a (arrel-type construction. The
(arrel type of cylinder construction ensures symmetry of the wall thic$ness around
the a,is of rotation and hence the wall thic$ness itself is relatively less than that used
in other type of construction.
2. I.P. Tur(ine 9asingG The IP tur(ine is split a,ially and is of single shell design. The
outer casing accommodates a dou(le flow inner casing. The steam coming from the
reheater is passed into the inner casing via admission
"
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(ranches which are symmetrically arranged in the top and (ottom halves of the outer
casing.
#. 3.P Tur(ine 9asingG The 3P tur(ine is of dou(le flow type. The casing is of triple
shell% fa(ricated construction. The outer casing consists of the front and rear end
walls% two longitudinal girders and a top cover. The inner shell of the inner casingacts as the guide (lade carriers for the initial stages of the tur(ine. The guide (lade
carriers of the 3P stage groups are so designed that% together with the inner casing%
they form annular ducts which are used for e,tractions.
4ig.- Tur(ine 'tages
TURBINE OIL SYSTEM
Purpose of ?il 'ystem
The tur(ine of system fulfils four functions. ItG
. Provides a supply of oil to the
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(II BOILER!"
I#$%&')$* !"
The (oiler installed in '.T.P.'. are made (y s &E3 . Each of the (oilers are single
drum% tangential fired water tu(e naturally circulated over hanged% (alanced draft% dry
(ottom reheat type and is designed for pulveri*ing coal firing with a ma,. 9ontinuous
steam output of 20 tonshour at 50 $gcm2 pressure and 5!0 degree cent. Temp. The
thermal efficiency of each (oiler at 96 is ". F. 4our no. ?f (owl mills have (een
installed for each (oiler. ?il (urners are provided for initial start up and sta(ili*ation of
low load .Two E.'.P. one for each (oiler is arranged to handle flue gases from the
respective (oilers. The gases from E.'.P.are discharged through 0 meters high chimney.
I./. fan and a motor is provided near the chimney to induce the flue gases. The (oiler is
provided with a (alanced draft consisting of two forced draft fans and two induced draft
fans. 4lue gases are utili*ed to heat the secondary air for com(ustion in the tu(ular typeair heaters installed in the (oilers. 'ince the (oiler furnace is maintained at a negative
pressure% to avoid atmospheric air entering the furnace a hydraulic pressure is maintained
at the furnace (ottom. The water filled in the stainless steel seal through the hydraulic seal
(etween the furnace ash hoppers and the water wall ring heater. Ade)uate clearance is
also provided for the downward e,pansion of the furnace. Ash is formed (y the result of
(urning of coal inside furnace. A small )uantity of ash is collected in the (ottom ash
hopper and considera(le amount of ash is collected in the E.'.P. and magnetic separator
hopper. This collected ash is e,tract and disposed off in a slurry form in the ash disposal
arc.
B+,*) $/&% +#' +**+%*/, !"
The (oiler also termed% as Jsteam generatorD is a container in which water can (e fed and
(y the application of heat evaporated continuously into steam. The heat source is o(tained
(y (urning the fuel% which is coal here in our case .The walls contained in the (oiler drum
flows through the down corner water walls and then through risers (ac$ to the drum. This
closed c$t. ovement of (oiler water is termed as circulation. The heat energy applied in
the furnace is a(sor(ed (y the water walls and water in this c$t. gets heated up .This give
rise to the formation of steam (u((le in the water walls and risers . The mi,ture of water
and steam will rises continuously and move to the steam drum due to its lightness. The
mi,ture of water and steam is continuously displaced (y the colder water. In the drumthere (y esta(lishing a natural circulation. As the mi,ture of water and steam ta$es place
in the steam separators and the saturated steam is led into the upper heaters for further
heating and water particles fall (ac$ into the drum water. After the feed control station the
feed water enters into the economi*er inlet header where the feed water is preheated
(efore entering the (oiler drum. The economi*er is located (elow the real hori*ontal super
heater in the (oiler near gas pass. The economi*er has a no. ?f sections composed of
parallel tu(e c$t. The flow direction of feed water in the economi*er is in counter flow
direction to the gas flow. The feed water coming out of the economi*er of the outlet
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header enters the (oiler drum. The (oiler drum is located at !!-m level. There are four
downcomers pipes
connecting the water side of the drum to the furnace lower water wall inlet headers. The
front and rear wall inlet header feed the front and rear furnace wall tu(es. The furnacesidewalls are fed (y the two side walls inlet header. The heat a(sorption ta$es place in the
water walls. As a result of heat a(sorption there will (e a mi,ture of water and steam in
the c$t. 7hich is collected in the outlet headers .A series of riser tu(es are provided to
carry the water and steam mi,ture from the water wall header into the drum where
separation of water and steam ta$es place .The wet steam which enter the drum from the
riser tu(es is collected in a compartment% formed (y internal (affles. 4rom here% the steam
is passed through too rows of tur(o separator which has a primary and a secondary stage.
In the tur(o separator water is thrown off and the steam passes through the screen
separators in the internal stage of separation.
4ig.- &oiler 'ystem
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(III E.S.P. !"
E.S.P THEORY
E.'.P. is a highly efficient device for e,traction of suspended particles and fly ash from
the industrial flue gases. WORKING PRINCIPLE !E.'.P can handle large volume of
gases from which solid particles are to (e removed Advantages of E.'.P. are G- igh
collection efficiency 3ow resistance path for gas flow Treatment of large volumes at high
temp.A(ility of cope with corrosive atm.An E.'.P. can (e defined as a device which
utili*ed electric forces to separate suspended particles from flue gases GWORKING
STEPS :Ioni*ation of gases and charging of dust particles igration of dust particles.
/eposition of charge particles on collector surface. 6emoval of paE.'.P. consist of two
sets of electrodes% one in the form of thin wire% called discharge or emitting electrode in
the form of plates. The emitting electrodes are placed in the center or midway (etween
two plates and are connected to-ve polarity of .=. /.9 source of order of #> 1=collecting electrodes are connected to K ve polarity. The voltage gradient (etween
electrodes creates CORONA DISCHARGE, Ioni*ing the gas molecules. The dust
particles present in flue gases ac)uire -ve charge and deposited on collecting electrodes.
The deposited particles are removed (y $noc$ing the electrode (y a process called
RAPPING DONE BY RAPPING MOTORS.
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(I COAL HANDLING PLANT !"
7agon tippler has rated unloading capacity of twelve (o, wagon per hour% includingshunting and spotting time of haulage e)uipment.
4or vi(rating feeders of capacity #50 tonshr. each have (een provided feeding unload
coal.
A steel hopper has (een provided in crusher house to receive coal and distri(ute it through
manually operated rac$ and pinion gate to three vi(rating screens of ">5 thr. capacity
each coal a(ove 200 mm si*e passes on granules for crushing and reduction in si*e. 9oal
(elow 20 mm si*e passes granular and discharged on to crushed coal conveyor (elt.
4ollowing permutation and com(ination of operation are possi(le with installed
system.To transfer all crushed coal received from crusher house to live storage pipe.To
transfer part of received crushed coal to plant and to (alance to storage yard.To deliver the
raw coal (un$ers part and received crushed coal mi,ed with (alanced coal from the livestorage pipe.To transfer the plant crushed coal at >50 Thr from the reclaim live pile and
simultaneously stoc$ and s rad.The vi(rating ons as stated a(ove can (e o(tained (y the
use of flap gates which are installed on various chute and two vi(rating feeders% installed
on tower. The coal carried on various conveyers shall (e main monitored to ensure proper
loading and distri(uting weightless and vi(rating feeders.
4ig.- 7agon Tippler
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4ig.- 9onveyor
( ASH HANDLING PLANT !"
The ash handling system provide for continuous collection of (ottom ash from the furnace
hearth and its intermittent removal (y hydro e
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the ash disposal pump house . Too separate discharge lines are provided one for each unit
(ut only one line is used . The ash slurry from the two units is ta$en in one discharge line
through electrically operated valves
(I GENERATOR
THEORY !"Tur(o generator manufactured (y &..E.3. is incorporated with most modern design
concept and constructional features which ensures relia(ility% easy and constructional and
operational economicity.The generator stator is a tight construction% supporting and enclosing the stator wdgs% core
and hydrogen coolers. 9ooling medium hydrogen is contained within a frame and
circulated (y fans mounted at either ends of rotor. The 8enerator is driven (y directly
coupled steam tur(ine at a speed of #000 r.p.m. The generator is designed for continuous
operation at rated ?P.
Temp. detector and other devices installed or connected within the c% permit the
measurement of wdgs% teeth core% and hydrogen temp. hydrogen pressure and purity in
9 under the conditions.
The 'ource of e,citation to rotor wdgs is thyristorised /.9. supply. The Au,iliary
e)uipment supplied with 9 suppresses and ena(les the control of hydrogen pressure
and purity% shaft sealing lu(ricating oils.There is a provision for cooling water in order to maintain a constant temp. of coolant
hydrogen which controls the temp. of wdg.% core etc. as per loads.
#
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4ig.- 8enerator
STATOR FRAME !"
The stator frame of welded steel frame construction which gives sufficient strength and
rigidity necessary to minimi*e the vi(rations and to with stand thermal gas pressure.
eavy end shields enclose the ends of frame and from mountings of generator (earings
and radial shaft seals. The frame is su(divided (y ri(s and a,ial mem(ers to form duct
from which the cooling gas passes to and from the radial ducts in the core and in
recirculated through internally mounted coolers. All the gas ducts are designed so a s to
reduce (alanced distri(ution of hydrogen to all parts of the core. The stator% constructed in
a single piece% houses the core and wedge. The hori*ontally mounted water cooled gas
cooler (eing so arranged that it may (e cleaned on the water side without opening the c
to atmosphere.
All welded
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The segment of insulating material is inserted at fre)uent interval to provide additional
insulation. The laminations are stamped out with accurately fine com(ination of ties.
3aminations are assem(led on guide (ass of group separated (y radial ducts to provide
ventilation passage. The ventilation ducts are disposed so as to distri(ute the gas evenly
over the core and in particularly to give ade)uate support to teeths. At fre)uent intervals
during stac$ing the assem(led laminations are passed together in powerful hydraulic pressto ensure tight core which is finally held (etween heavy clamping plates which are of non
magnetic steel. :se of non-magnetic steel reduces considera(ly the heating of end iron
clamping to the footed region of the core is provided (y pressing figures of non-magnetic
steel which are welded to inner periphery of the clamping plate.
In order to reduce the losses in the end pac$ets special dampers are provided at either end
of core. ostly dampers are provided to prevent hunting in A9 achines.
STATOR WINDINGS !"
'tator wdgs are dou(le star layers% lap wound %three phase %short pitch type. The top and(ottom are (ra*ed and insulated at either and to form turns. 'everal such turns form a
phase. Phases are connected to form a dou(le star wdg. The end wdg formed on involute
shaped ends% is inclined towards 9 a,is (y 20% thus form a (as$et wdg. 7ith total
induced conical angle of !0. /ue to this stray load losses in the stator ends to *ero.
The arrangement of complete stator wdg. electrical c$t. is viewed from tur(ine end of
generator and rotor wdgs. 'lot num(ering is cloc$ wise from tur(ine end. The top (ar in
slot no is identified (y the thic$ line. End wdgs will (e sealed against movement of
short circuit (y (oth a,ial and peripheral (racing. The later consist of hardened glass
laminated (loc$s inserted (etween ad 6T/Ds
(etween the coil side in the stator slots with > spacers and # 6T/ are there in the statorcore with # spacers.
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The location of temp. detectors are in three phases i.e. in the center of
9% in each region of machine and midway (etween them. The detectors in the stator
slots are distri(uted uniformly in all three phases. easurement of temp. in hydrogen
cooling water for hydrogen coolers and metals is as G-
'i, 6.T./.s are provided% on at the inlet of each of " individual
hydrogen coolers elements for measurement of temp. of hot hydrogen% similarly " 6.T./.sare provided% one at outlet of each of si, individual cooler elements. ?ne 6.T./. along
with one spacer is provided in the lower part of stator frames for measurement and
signalisation of hot hydrogen.. " 6.T./.s are provided one at the outlet of si, individual
cooler elements for measurement of cooling water at the outlet of hydrogen cooler
elements.
ROTOR !"
6otor shaft consists of a single piece alloy steel forging of high mechanical and magneticproperties performance test includes G-
Tensile test on specimen piece.
'urface e,amination
'ulphur print test.
agnetic 9rac$ detection.
=isual e,amination of the (ore.
:ltra sonic e,amination.
'lots are milled on the rotor forging to receive the rotor wdg. Transverse slots are
machined in the pole faces of the rotor to e)uali*e the moment of inertia in the direct and
)uadrilateral a,is of the rotor with a view of minimi*ing the dou(le fre)uency vi(rationof the rotor. The fully (ra*ed rotor is dynamically (alanced and su(
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(II CONDENSER
T/ #)$*, & )'/#,/% +%/!
. To provide lowest economic heat re
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4ig.- 9ondenser
#50F capacity condensate pumping sets are installed for pumping the condensate from
ondenser to the deaerator! through low-pressure heaters. Two pumps are for normal
operation and one wor$s as stand (y pump.
(III TRANSFORMER !"
GENERATOR TRANSFORMER !"
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Type of 9ooling G ?4A4 ?A4 ?A
6ating of .=.=A G 250 >5 25
6ating of 3.= =A G 250 >5 25
o. load voltage .=. 1.=. G 2!0
o. load voltage 3.=. 1.=. G 5.>53ine current .=. amps G "02.2
3ine current 3.=. amps. G ;>5.5
Temp. rise oil 9 G !09
Temp. rise wdgs. 9 G 55 50 50
9ustomer G 6.'.E.&
Phase G #
fre)uency G 50 *
9onnection sym(ol G y n d l
Impedance volts 250 =A ?6 TAP F G !.5>F
THEORY !"
A L-mer may (e defined as an e)uipment (ased on electromagnetic induction% alternating
voltage and current without affecting the fre)uency. It is an static e)uipment i.e. it has no
mova(le lim(s.
The fundamental theory of L-mer is that if on a magnetic core Iron 9ore% two windings
are placed then the current produced in primary wdg. ?n account of alternating voltage%
imposed induced voltage. E secondary and I secondary in secondary wdg.
T/ ),*,$, & $& -+%$, !"
MUTUAL FLU7G- 7hen flu, path is wholly limited in the core and which thereforelin$s the two wdgs.
LEAKAGE FLU7G- 7hose path partly in air and therefore lin$s only the primarywdgs .
The ratio of lea$age flu, to mutual flu, depends on the relative reluctance of their
respective paths which in turn is a function of saturation of core and the magnitude of the
current. A phase L-mer adopt this core. The three phase L-mer can (e accomplished (y
using a three phase L-mer or (y interconnecting three single phase L-mers units to form athree phase (an$.
7"8/% )+# 9/ )+,,**/' +))&%'*#0 $& )&%/ ),$%)$* !"
9ore form of construction
'hell form of construction
;
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In case the core form of construction agnetic steel punching are arranged to provide a
single path magnetic circuit. igh and low voltage coils are grouped on each of vertical
(y of core. In this way the mean length of turn for wdg. Is comparatively short while
magnetic path is long.
4or shell form of construction all wdg. of each phase are formed into a single with
magnetic punching assem(led so as to encircle each side of the wdg. 6ings. The meanlength of the turn is used usually linger compared to the core form of wedg. /esign which
the iron path is shorter.
In the larger si*e of L-mer% shell construction is )uite appropriate as compared to small
si*e transformers where core type construction is preferred.
A#&$/% $-/ & 7"8/% )+,,**)+$* *, 9+,/' )&&*#0 !"
In a L-mer% the losses in the core and wdgs iron and copper losses are transferred% to the
oil in the form of oil and heat in turn is carried (y am(ient air either (y natural or forced
convection. The overall transference of heat is (y conduction% convection and radiation.The oil in the duct and at the surface of wdg. And core ta$es up heat (y conduction and
transform it (y convection currents to the tan$ and supplementary coolers from which it is
dissipated (y conduction and convection or (y convection and radiation.
(I7 SWITCH"YARD
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Two 220 1= (uses have (een provided in switchyard and are interconnected through a
(us coupler. Each of the two 0 7 generator is connected to this system through a step
up 25 =A% 2!0 1=% yd gen. L-mer.
4our line feeders ta$e off from 220 1= switch yard to 'a$atpura grid su(station. Two
1ota and other two to eerapura Caipur grid su(station. Each of the four feeders have
(een provided with a (y pass isolator which is connected across the line (rea$er and(rea$er isolator.
T/ &$0&*#0 //'/%, +%/ !"
The features descri(ed a(ove for feeders facilitates ta$ing shut-down of any one line
(rea$ers at a time for maintenance without power flow in line. The e)uipments in the
switchyard are G-
. 9ircuit (rea$er
2. Isolators
#. Earthing Isolator!. 3ightening arrestors
5. 9urrent L-mer
". Potential L-mer
2
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4ig.- 'ystem overview
CIRCUIT BREAKER !-
Each of the 8%T.% '.T.% line feeder and (us coupler is provided with circuit (rea$er with is
rated for 25! 1=% 2500 amp and it can (rea$ a c$t either in load conditions or in on load
conditions. The c$t. &rea$er can also interrupt fault currents% fly current automatically for
#phase system% phase c$t - (rea$ers are used. Each pole of c$t. &rea$er comprises of one
or more interrupters. The Interrupters are mounted on support insulators. The interrupter
encloses a set of fi,ed and moving contacts can (e apart (y means of operating medium.
The produced (y the separation of current carrying contact is interrupted (y a suita(le
medium and (y adopting suita(le techni)ues for arc e,tinction. The 9&s can (e classified
according to the medium of are e,tinction. They are as follows G
AIR BREAK CIRCUIT BREAKER !-
In these 9.&. the contact% separation and are e,tinction ta$es place in air at atm. Pressure.
The 9& employs the high resistance interruption principle. The are is rapidly lengthened
(y means of are runners and are chutes and the resistance of the are is increased (y
cooling lengthening and splitting the arc. The arc resistance increases to such an e,tent
that the voltage drop across the arc (ecomes more than the supply voltage and arc get
e,tinguished
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:. CONCLUSION
It was really worth spending #0 days at 'TP'% 'uratgarh as I went through Electricity
8eneration. The practicality of the training was really fruitful as I was a(le to understand the
real time applications of various electronic instruments. oreover while wor$ing over there I
also gained a very rich e,perience of wor$ing in a government station as well as people. It
also gave me the $nowledge of professional fields.
It was a memora(le e,perience for me to wor$ in the station as I have (een listening to it
from my childhood.
I have learned all a(out the wagon% wagon-tippler% side-arm-charger% conveyor% rootery-vecor
% &oiler% Tur(ine% Transformer and 8enerator.
'.T.P.'. is a very large plant and it is very difficult to ac)uire complete $nowledge a(out it in
a short span. I have tried to get ac)uainted with overall plant functioning and main conceptsinvolved therein.
I have summari*ed all the things% which I saw + learned at '.T.P.'. in the training session.
It ma$es us to reali*e that engineering is not
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REFERENCES
. httpGen.wi$ipedia.orgwi$iThermalMpowerMstation
2.httpGwww.(entley.comsaIPromoAutoP3AT'1I/N9E?MIMAP3ATM8?83E0>+7T.srchN+gclidN9)!Mu)vypc94OEspAodrwr?'O
#. &oo$s G Electrical achines P.'. &him(ra !thEdition th6eprint-200;
!. Electrical achines C.&. 8upta 2thThoroughly 6evised Edition
2!
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