SYLLABUS - SEMESTER 1

Well come ceremony will be organized for introduction with HODs and higher management. Mentors will be finalized
to each student and visit to plant and important locations will be arranged.

Module 1 – Induction to program & Industrial Safety (1 week)

Process and electrical safety classes

Accidents Causes & Factors, Cost of Accidents, Accident Prevention, Investigation of Accidents, Reporting and
Recording Systems for Accidents

First Aid Basics of First Aid, how injuries caused in lifting, falls etc.

Fire Detection and Protection system Fundamentals of Fire, Fire Fighting Equipments and Systems, Fire
Extinguishing Methods, Demonstration of various Fires

Industrial Safety & Hazards and safety system in plant

Industrial Hazards, Protective Clothing and Equipment, Safe Working Practices in Power Plant, Permit to work
system, Safety in Movement and storage of Materials, House Keeping, Safety Rules.

Module 2 - Power Plant Familiarization (08 weeks)

UNIT I (BRIDGE COURSE)

Thermodynamics Basic Concepts and Gas Laws, Heat and Work, Specific heat, Enthalpy, Internal Energy,
Entropy & Equations of State, Laws of Thermodynamic Processes, Thermodynamic Process

Fluid Mechanics Properties of Fluids, Pumps, Fans Heat Transfer Basic Concepts of Heat Transfer, Modes of
Heat Transfer, Types of Heat Exchangers, Thermal Insulation

Thermal Engineering Steam and Gas cycles, Flow through nozzles, Function, working principle,
classification, Basics of Boiler, Turbine & Associated Systems

UNIT II (GENERAL INTRODUCTION)

Site Selection site availability, Raw Material, Fuel, Load evacuation, Water Transport, Pit Head Station, Air
Pollution, Topography, Skilled Manpower

Coal Types of coal and their characteristics, their suitability for different kinds of Boilers, Alternations in firing
methods due to change of coal composition.

Coal to Electricity Coal / Air / Flue / Gas / Water / Steam Path, Brief description of main equipment involved in a
Thermal Power Station.

General Layout of a Thermal Power Station Block Diagram of main equipment’s, location and layout of Boiler,
Turbine, Generator and their Auxiliaries.

Steam Cycle Theory Carnot Cycle, Rankine Cycle, with reference to a specific unit 500/250/210 MW, steam
properties.

Combustion Theory Definition, combustion requirements, factor influencing combustion, composition of fuels,
gross and net calorific value.

Water Treatment System: Soft Water, Circulated Water, Cooling Water, and D.M. Water.

Coal Handling System Location and layout, main equipments and their functions, coal transportation,
preparation, storage and reclamation, MGR systems, safety aspects, fire prevention and fire fighting in Coal
Handling Plant.
Ash Handling System Fly ash handling system, bottom ash disposal system, ash handling plant operation, ash
handling pump, disposal of ash slurry, utilization of ash.

Fuel Oil Systems Location and site selection, types of fuels oils used, main equipments and their functions,
transportation, handling, storage, fuel oil preparation before firing.

UNIT III –BOILERS

Description of Boiler Classification and types, arrangements of main boiler, fundamentals of boiler design,
location of various pressure parts.

Boiler Circulation Theory Water walls, boiling phenomena, nucleate, film boiling, natural / controlled / forced
circulation.

Construction Details of Super Heaters, Re-heaters, Economizers and De-super heaters.

Steam Separation Theory Boiler Drum & its internals.

Draught System: Theory of natural, induced, balance and forced draught, drought loss, stack effect.

Pulverizes and Feeders Classification of mills, constructional features of bowl mill, pulverization of coal,
factors affecting milling plant performance, coal feeders and its type.

Fuel Firing Arrangements and Burners Corner, front and rear wall firing, Direct and indirect firing, details of
coal and oil burners, burners tilting mechanism, atomization of fuel oil in oil burners and igniters.

Circulating Water System Open / closed system, CW Pumps, Cooling Towers, CT Pumps, CT Fans.

UNIT IV - STEAM TURBINES

Steam Turbines: Classification of Turbines, Metallurgical considerations, working principles, Description of

Turbine Lubrication Oil System: Construction and working principles of main oil pumps, starting oil pumps,
AC, DC oil pumps, Oil coolers

Steam Condensation and Condensers: Film wide / drop wise condensation, direct / indirect condensation and
vacuum creation

Regenerative Feed Heating System: Working Principal and constructional details of L. P. Heaters, Deaerator, H.P.
Heaters, GSC, Ejector. Coolers, Deaerator, Turbine Oil System

Turbine Governing System: Types of Governing System, various components, systems and their functions, oil
circuit for governing system, overall working of governing system with reference to load throw off, load raising,
General, LMW Turbine, KWU Turbine,

Automatic Turbine Run Up System (ATRS) Fire Resistant Fluid, comparisons Between 500MW& 250/210MW
Turbines

HP / LP Bypass System and PRDS HP / LP bypass circuit and its utility, various interlocks for operation, oil
circuit in HP / LP by pass system, auxiliary PRDS circuit, pressure regulating system of PRDS circuit

UNIT V -BOILER AND TURBINE AUXILIARIES

Power Station Pumps Classification of pumps, centrifugal pumps, and positive displacement pumps, Boiler
Feed Pump, Function of BFP, Constructional details

Various Fans and their salient features Construction details / lubricating oil system for PA Fan, FD Fan, ID
Fan

Air Pre-heaters Types and functions, constructional details, SCAPH, soot blowers

Furnace Safeguard Supervisory System (FSSS) Description of Field equipment’s (no C&I)
Electrostatic Precipitator (ESP) Need of fly ash separation, working principle, corona effect, constructional
details, rapping mechanism

**ONSITE VISITS: There shall be regular onsite visits to the Power Plant.

UNIT VI (BRIDGE COURSE)

Growth of Power Industry after Independence Organizational Electricity Industry structure in India, Electricity
Generation, Consideration and Location of Large Thermal Power Plants, Station layout, Power sector –
Highlights & main Achievements

Basic Electrical Science Electrical engineering materials, conductor, insulator, magnetic materials, resistive
materials, Basic Quantities of Electricity V,I,P,Q,S, their measurements, Introduction to R-L-C elements
Electromagnetism, Principles of AC and DC, DC Power Supply , single phase and three phase supply systems,
Systems, series, parallel circuits, short and open circuits concepts, faradays law, Flemings left and right hand
rule, star-delta connections

Alternator (Only introduction) Basic generation action, D.C. and A.C. generator Principle, description,
constructional details of Generators and their application in power plants

AC Motors (Only introduction) Classification, Principle of AC Motors, Constructional features of AC motors, its
application in power plants.

Transformers Only introduction) Working principle of Power Transformers, Type of Transformers efficiency and
regulation, Distribution, power Transformer

Switchyard Equipment’s Only introduction) HT/ LT switchgears, their need, qualities, Bus Bars, Circuit
Breakers, Types of circuit breakers, Isolators, Protective relays

UNIT VII -GENERATORS

Generator Constructional Details: Basic principle of electricity generation, development of generator design,
construction details of rotor, stator etc.

Hydrogen Cooling System and Stator Water Cooling System: Different types of cooling arrangements for
rotor and stator, selection and properties of coolant, air cooling, hydrogen cooling, stator water cooling,
charging / purging cycle.

Hydrogen Seal Oil System: Details of the system, function and purpose of differential pressure regulator and pressure
oil regulators, types of hydrogen seals and their constructional details.

Generator Excitation System and AVR: Principles, simple arrangement of exciter and its field winding,
classification of excitation system and exciter development, high frequency excitations system – their merits
and demerits, automatic voltage regulator and its control. Introduction to static excitation system &
description performance of static excitation system, thyristor characteristics & its application in static
excitation system, limiters in static excitation system, excitation transformer, Operational aspects of static
excitation system, salient features of static excitation system.

Generator: Seal oil scheme, Hydrogen scheme, stator water cooling schemes, excitation
arrangements,

Protection of generators: different methods of protection

UNIT VIII - TRANSFORMERS AND OTHER ELECTRICAL SYSTEMS

Transformers: Working Principles, Various types of transformers used in a power station,

Motors: Fundamentals, constructional details of HT / LT motors, various motors used in Power Stations speed
control methods
HT-LT Supply System / DC Supply System: A typical layout of 6.6 kV, 3.3 kV and 415 kV supply system in TPS,
DC supply system in a TPS.

Auxiliary Power Supply: 6.6 KV Schemes 420 V Schemes, arrangement of breakers, buses, DC system, battery
bank arrangement

Switchyard: A typical layout of switchyard of a thermal power station, bus system, isolators, CTs, PTs,
Earthing, Oil Circuit Breakers, Air Blast Circuit Breakers, SF6 Circuit Breakers, GT to feeder line arrangement,
locating various transformers (GT, UAT, SAT, CTO, PTO), switchgears, isolators, earthing arrangement buses etc.

** ONSITE VISITS: There will be regular visits to plant after classroom teaching

Module 3 : Power Plant Briefing & Scheme Tracing work visit ( JPL 250MW & 600MW) (04 week)

UNIT I (POWER PLANT BRIEFING & SCHEMES TRACING-1)

Scheme briefing in classroom: Boiler Drum connections, feed regenerating heating system, air, and flue gas
path. Classroom briefing on fuel oil system and milling system Classroom briefing on mainstream, cold reheat;
hot reheat lines, condensate & feed water lines, BFP, CW schemes. Classroom briefing on hydrogen cooling,
stator water, seal oil, switchyard, GT, UAT, breakers, bus bars, 66 KV / 420 KV switchgears.

Scheme Tracing: Coal handling receiving points, stocking lines, weighing, sampling, screening, crushing, bunker
filling, conveyors, tension arrangement for conveyors.

Oil Handling: Unloading arrangements, oil tank mountings, oil pump house connections, tank heating and
tracing heating, pipe line layout with provisions for expansion

Boiler Feed Water Schemes: Feed control station arrangement, economizer connections, economizer re-
circulation lines, boiler drum water wall connections, drain header, blow down lines, CBD, IBD expanders,
SH/RH attemperator station.

Air and Flue Gas Schemes: Location of FD, PA, Seal Air, IF Fans, Fan control devices, damper arrangements,
primary air, secondary air and flue gas paths, Scanner air, seal air schemes, Wind box and burner arrangement,
Fuel Schemes, Scheme of RC bunkers and RC feeders, coal mill connections, Light oil and atomizing air system,
location of trip valves, control valves, nozzles valves, igniters, Heavy oil and atomizing steam system

Water Treatment Plant Raw water tanks to DM water storage tanks, arrangement of Pr. Sand / Activated
carbon filters, cat ion, anion, mixed beds, degasifying lines, provision for back cooling, regeneration,
phosphate and hydrazine dozing scheme.

Ash Handling: Bottom Ash disposal, BAH (bottom ash hopper) arrangement, clinker grinder, HP/LP water
injection, fly ash disposal arrangements, ash slurry pump house, slurry sumps, pump connections.

UNIT II (POWER PLANT BRIEFING & TRACING-2)

Steam Schemes MS, CR & HRH lines up to turbine control valves including HP/LP by pass, location of safety
valves, vents and drains, auxiliary PRDS schemes, auxiliary steam distribution, soot blowing steam lines

Steam Extractions and Drains: Schemes of turbine extractions, FCNRVS, heater drain connections, HP/LP
drips. Schemes for heating flanges and studs, Steam connections / condenser air line connections to ejectors,
unit drain tank / flash tank connections.

Condensate and Feed Water Schemes: CEP connections, scheme of condensate flow, ejectors, gland steam
coolers, LP heaters, de-aerator connections. Scheme of feed water flow, BFP connections, feed water
connection to HP heaters, location of valves, interconnections, bypass arrangement for heaters

Turbine Oil System: Turbine lube Oil schemes, lube Oil purification schemes, location of MOT & lube Oil
pumps, oil coolers, cooling water connections

CW System and Cooling Towers: locating moving screens, CW pumps, venting arrangements, valve
locations, chlorination schemes.

Regards
Sabu Isac
Prof JIPT
8978880920

Jindal Institute of Technology

Tamnar