Appendix I

Syllabus for the operating and supervisory staff engaged in the operating

and maintenance of the Thermal Power Stations

GENERAL COURSE FOR ELECTRICAL AND MECHANICAL

Item No Particulars Number of hours
I.  Concept of modern thermal station:

Central Station and utility  systems, base load and peaking stations, concept of unit system, typical thermal cycles, parameters, heat rates, fuel rates, steam rates, typical heat balance of boiler, turbine and generator.

4
II.  Choice of location of large thermal station:  Site availability water requirements, fuel, load centres, transport facilities, air pollution, topography, choice of size of generating units.

 

3
III. Plant layout in large central station including machine 3
IV.  Constructional details of large pulverised fuel boilers and auxillaries:

(i) Water and steam drums, heaters and tubes.

(ii} Types of furnace and firing arrangement, burner details.

(iii) Economisers, primary, secondary , superheaters, reheaters
and attemperators.

(iv) Forced draught, Induced draught, primary Air exhaustor
and gas re-circulation fans, compressors.

(v) Types of coal mills, (ball/recess, balltube, bowl roller)
stoker, coal feeders.

(vi) Air preheaters, Lunstorm, tubes, steam.

(vii) Dust extraction plant electrostatic, mechanical.

(viii) Soot blowers : steam/ compressed air operated.

(ix) Station compressed air system-reciprocating and rotary
compressors.

(x) Oil handling and firing equipment.

(xi) Boiler mountings, gauge glasses, safety valves, stop
valves, start-up devices stampling, chemical dosing,  continuous blow down.

(xii) Refractories and laggings as used in modern power
stations.

16
V.  Turbine and auxiliaries, constructional details:

(i) Principle of operation, heat conversion cycles, types of

(ii) Casing steam chests, wheel blading, nozzels, diaphragms,

(iii) Condenser and vacuum extraction plant, ejectors.

(iv) Lubrication system, pumps, coolers, filters, shaft turbine

(v) Feed water booster and extraction and cooling water

(vi) Low pressure and high pressure feed water heaters, deaerators and evaporators.

(vii) High and low power by-pass systems

(viii) Oil purification unit.

 

9
VI.  Alternators and excitation systems:

(i) Constructional details of alternators, methods of cooling
(Hydrogen/ air cooling).

(ii) Main and pilot excitors voltage regulators, types and characteristic, amplifier and magnetic amplifier.

(iii) Methods of grounding.

 

6
VII.  Coal handling plant:

 Tippler, hoppers, vibratory feeders and conveyors" crushers, magnetic separators and pulleys

6
VIII.  Ash and slag handling plant: Electrostatic precipitators, Methods  of conveying pneumatic, vacumatic, hydraulic, bucket 2
IX . Water sources, treatment:

Raw water pumping station,  domestic, circulating and boiler makeup water treatment, River salinity, local water conditions, their variations in different seasons and effects on power station operations.

7
X.  (i) Fuels:

Solid, liquid and gaseous fuel analysis. 
(ii) Coal-types and suitablility for different kinds of boilers-
alterations in firing methods due to change of coal composition.
 

6
XI.  Basic flow diagrams in power station practice:

(i) Coal and fuel oil cycle.
(ii) Air and gas cycle.
(iii) Fly ash and slag handling arrangements.1
(iv) Condensate and feed heating cycle (from condenser
hotwell up to economiser).
(v) Steam and water cycle (from economiser to turbine inlet).
(vi) Circulating water cycle.
(vii) Hydrogen filling in generator and hydrogen gland
sealing of generator.
(viii) Bearing cooling system.

8
XlI.  Direct and closed cooling circuits, cooling towers types and  characteristics 2
XllI.  D.C. and A.C. power supply for auxiliaries arrangements of units and station boards, station lighting and automatic changeover 4
XIV. Transformers:

 Main transformers, interconnecting  transformer, station/unit transformers, voltage grounding transformers, types of connections paralleling top-changer gear.

5
XV.  Outdoor switchyard single line diagrams busbars circuit 
breakers, isolators, current transformers, potential transformers lightning arrestors, grounding.
5
XVI.  Indoor and outdoor switch-gear :

 Types bulk oil, minimum oil, air blast, air break constructional details.

3
XVII.  Instrumentation and measurements:

 Constructional details of  measuring instruments for pressure, flow, temperature, level, draught, vibration, eccentricity, conductivity, pH Value, differential expansion, oxygen analyser, current, power, reactive power, frequency, energy, winding temperature.  Auto-controllers, hydrogen purity meter, Axial shift indicator and recorder, flue gas analysers, Megger-its use for primary detection of faults.

16
XVIII.  Operation, control and supervision

(i) General boiler start-up procedure

(ii) Operation of boilers under different loading conditions,

(iii) Banking and preservation of boilers.

(iv) Demonstration wherever possible through simulators of

(v) Handling of boiler under emergency conditions, (such as

(vi) General start-up procedure for high pressure multi-

(vii) Handling of turbine, generator and auxiliary plant under feed water heater high levels, excessive vibration, water or oil

(viii) Alternator-synchronising, loading, parallel operations,  

15
XIX.  Controls and Protection-Sequential operation and interlocks :

(i) Boiler and auxiliaries 2

 
  (ii) Turbines and auxiliaries  
  (iii) Combustion control-pressure, fuel, air and feed heating 2 2
  (iv) Analysis of feed and Boiler water, fuel gas at station 4
  v) Feed water and feed heating cycle controls 2
  (vi) Turbine governing, speed setting, speed drop setting and 3
  (vii) Generator protection, under-voltage, over-voltage, 4
  (viii) Importance of sequential inter-locks 2
  (ix) Transformer protection differential, overload, earth faults,  high temperature, buchholz with types of the relays used. ,
 
4
  (x) Types of motors and variable speed drive and speed 4 4
  (xi) Various types of pumps and their starting and control

(xii) Stream temperature control

(xiii) Furnace purging
 

3
XX. Fire-fighting and multifier type protection. 3
XXI.  General safety precautions, treatment of electrical or acid  alkali burn, permit to work, first-aid. 3
XXII.  Indian Boiler Rules, Factory Act, Indian Electricity Act, 1910,  Electricity (Supply) Act, 1948, Indian Electricity Rules, 1956, and other statutory regulation concerning Power Stations (General outline) 4
XXIII  General plant maintenance procedure, PERT /CPM Methods,  Power Station records and calculation of efficiency.  
XXIV  Various types of valves, traps, their constructional details and application 2
XXV.  Cranes, hoists, characteristics and controls 3
XXVI  Personnel management, duties and responsibilities, Labour  Laws and Labour Welfare. 
 
6
XXVII.  Broad principles of material management and inventory control. 4
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