A

Summer Internship Report

On

Adani Power Mundra Limited

(10 June 2019 – 15 July 2019)

Submitted by:
Siddharth Gupta
B.Tech + M.Tech
8th Sem.
Electrical Engineering

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S.NO Title Page No.

1. Adani Group 3
2. Adani Power Limited 5
3. Adani Power Mundra Limited (APMuL) 7
4. Thermal Power Plant 8
5. Working of power plant 9
6. Technology used 10

7. Phase 1 and Phase 2 11

8. Specifications of GT,ST,UAT,GEN. 12
9. Phase 3 and Phase 4 17
10. Specifications OF GT,ST,UAT,GEN. 18
Electrical Department of Plant 22
10. Internship Assessment 32
11. Conclusion 33

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Adani Group

• Adani Group is an Indian multinational conglomerate headquartered

in Ahmedabad, Gujarat. It was founded by Gautam Adani in 1988 as
a commodity trading business with the flagship company Adani Enterprises
Limited previously Adani Exports Limited.
• Mr. Gautam Adani is the chairman of this group.
• The Adani Group commenced as a commodity trading firm in 1988 and
diversified into the import and export of multi-basket commodities.
• The Group's diverse businesses include energy, resources, logistics,
agribusiness, real estate, financial services, defense and aerospace.
• This group has annual revenue of over $11 billion with operations at 70 locations
in 50 countries.
• With a capital of 5 lakhs, the company was established as a partnership firm
with the flagship company, Adani Enterprises Limited, previously Adani Exports
Limited. In 1990 the Adani Group developed its own port in Mundra to provide
a base for its trading operations.
• It is India's largest port developer and operator with ten ports and terminals
including Mundra Port, the largest commercial port of India.
• Through a joint venture with Wilmar International in Singapore, the Group co-
owns India's largest edible oil brand, Fortune.
• The group's second phase started with the creation of large infrastructure
assets. The company established a portfolio of ports, power plants, mines, ships
and railway lines inside and outside India.
• Adani power is the largest power producer of India.
• In 2015, Adani was ranked India's most trusted infrastructure brand by The
Brand Trust Report 2015.
• The Group operates mines in India, Indonesia and Australia and supplies coal to
Bangladesh, China, and countries in Southeast Asia.
• The company has contributed to the economy of Bunyu, North Kalimantan,
Indonesia by producing 5.6 MMT of coal in 2018-19.
• The Group has made the largest investment by an Indian company in Australia
at the controversial Carmichael coal mine, Galilee Basin, Queensland.

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• This Group is the first in India to build a high-voltage direct current (HVDC)
system.

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ADANI POWER LIMITED

• India's first company to achieve the supercritical technology.

• Adani Power Limited is the power business subsidiary of Indian Conglomerate
Adani Group with the head office at Ahmedabad, Gujarat .
• The company is India's largest private power producer, with capacity of 10,440
MW and also it is the largest solar power producer of India with a capacity of
688 MW.
• Adani Power was ranked as the 73rd largest corporation in India in Fortune India
500 list of 2018.
• The company operates five supercritical boilers of 660 MW each at Mundra,
Gujarat & five 660 MW units at Tiroda, Maharashtra. It also operates a mega
solar plant of 40 MW at Naliya, Bitta, Kutch, Gujarat.
• Adani Power has become largest thermal power generating company in the
private sector, and the Mundra plant has become India's largest power plant
with capacity of 3,300 MW

Operations:

• Mundra Thermal Power Station : 4,620 MW (4x330 MW + 5x660 MW) coal-

based thermal power plant at Mundra, Kutch district, Gujarat.
• Kawai Thermal Power Station :1,320 MW (2x660 MW) coal-based thermal
power plant at Kawai village, Baran district, Rajasthan. This plant is fully
functional
• Udupi Power Plant : 1,200 MW (2x600 MW) coal-based thermal power plant
at Padubidri, Udupi district, Karnataka. Both units are fully functional since
September 2012. Adani Power acquired this power plant from Lanco
Infratech in August 2014 for Rupees 6,000 crores.
• Tirora Thermal Power Station : 3,300 MW(5x660 MW) coal-based thermal
power plant at Tirora, Gondia district, Maharashtra.
• Kamuthi Solar Power Project : 648 MW solar power station.
• The company produces 40 MW of solar power in Bitta, Kutch Gujarat.

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Page | 6
ADANI POWER MUNDRA LIMITED (APMuL)

• The power plant at Mundra in 4 phases with the first 3 phases consisting of 2 units
each and Phase IV consisting of 3 units, making it a total of 9 units with the division
4 x 330 MW (Subcritical Technology) + 5 x 660 MW (Supercritical Technology)
adding up to a total of nameplate capacity of a massive 4620 MW.

• Adani Power created history by synchronizing the first Indian Supercritical

Technology based 660 MW generating unit at Mundra, Gujarat.

• The Mundra Power Project is also the fastest project implementation ever by any
power developer in the country with a record completion of inception to
synchronization within 36 months.

• Phase III of the Mudra Project, which is based on Supercritical Technology, has
received ‘Clean Development Mechanism (CDM) Project’ certification from United
Nations Framework Convention on Climate Change (UNFCCC).

• This is the world’s first Thermal Project based on Supercritical Technology to get
registered as a CDM Project under UNFCCC.

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THERMAL POWER PLANT

Basic components of plant are:

1. Cooling tower 11. High pressure steam turbine 21. Reheater

2. Cooling water pump 12. Deaerator 22. Combustion air intake

3. Transmission line (3-phase) 13. Feedwater heater 23. Economiser

4. Step-up transformer (3-phase) 14. Coal conveyor 24. Air preheater

25. Precipitators/dust
5. Electrical generator (3-phase) 15. Coal hopper
collectors/scrubbers

6. Low pressure steam turbine 16. Coal pulverizer 26. Induced draft fan

7. Condensate pump (to deaerator) 17. Boiler steam drum 27. Flue-gas stack

8. Surface condenser 18. Bottom ash hopper 28. Condensate pump (to boiler)

9. Intermediate pressure steam turbine 19. Superheater

10. Steam control valve 20. Forced draft fan

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Working OF Power Plant

• Coal is transported from coal mines to the generating station by conveyer belts.
• Bituminous coal or brown coal is used as fuel.
• The coal is stored in either 'dead storage' or in 'live storage'. Dead storage is
generally 40 days’ backup coal storage which is used when coal supply is
unavailable. Live storage is a raw coal bunker in boiler house.
• After cleaning and converting coal into powdered form by various methods
respectively goes for combustion into the boiler.
• The mixture of pulverized coal and air (usually preheated air) is taken into boiler
and then burnt in the combustion zone
• On ignition of fuel a large fireball is formed at the center of the boiler and large
amount of heat energy is radiated from it.
• This heat energy is utilized by converting the water into steam at high
temperature and pressure
• The flue gases from the boiler make their way through superheater,
economizer, air preheater and finally get exhausted to the atmosphere from the
chimney
• High pressure super heated steam is fed to the steam turbine which causes
turbine blades to rotate
• The pressure and temperature of the steam falls to a lower value and it expands
in volume as it passes through the turbine. The expanded low pressure steam is
exhausted in the condenser.
• The exhausted steam is condensed in the condenser by means of cold water
circulation
• the steam loses its pressure as well as temperature and it is converted back into
water
• The steam turbine is coupled to a generator. When the turbine rotates the
generator, electrical energy is generated.
• This generated electrical voltage is then stepped up with the help of
a transformer and then transmitted where it is to be utilized.

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 Technology used

Here at Adani Power uses two types of technologies:

1. Supercritical technology:

• The supercritical technology is the thermodynamic state where there is

no clear distribution between the water and the steam phase between
Rankine cycle.
• Water reaches to steam state at a critical pressure above 22.1 MPa at
374 deg. C
• 660 MW unit uses this technology in plant.
• Higher unit cycle efficiency.
• Overall lower life cycle unit cost.

2. Sub-critical technology:

• It is the thermodynamic state vapour + liquid intermediate state is

present in the Rankine Cycle.
• This state occurs when the operating parameters are below the
critical point of water.

• Difference between sub-critical and supercritical technologies boiler:

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Phase 1 and Phase 2
• Here at Phase 1 & 2 there 4 units which have an output of 1320 MW
(i.e. 4*330MW).

• Main parts of UNIT 1,2,3 & 4 CONSISTS OF:

Generators
Excitation Transformers
Station Transformers
Generation Transformers
Unit Auxiliary Transformers

Unit Flow Diagram:

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SPECIFICATIONS: (NOTED)

• Generator

• An alternator is an electromechanical device that converts mechanical

energy to alternating current electrical energy.
• Most alternators use a rotating magnetic field.
• Generator is connected withal HP, IP and LP turbines so when the turbines
rotates by the pressure of the steam of the generator also rotate and due to
magnetic field, it generates electricity.

• In 330 MW unit the generator is connected with one HP turbine, one IP

turbine and one LP turbine

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• Generator 330 MW:

Active power 330 MW

Apparent output 388 MVA

Rated Terminal Voltage 24 KV +/- 5%

Rated Frequency 50 Hz +3 to -5%

Rated Power Factor 0.85 lagging

No. of phases 3

Phase Connection Star

Rated Speed 3000 rpm

Reference Standard IEC – 34

Live Terminal brought out 3

Neutral terminal brought out 3

Short Circuit Ratio 0.60 min.

Short Time overload Capability 150% for 15 sec

Cooling of stator core Hydrogen

Over Speed 120% for 2 min.

Cooling of Stator Winding DM water

Type Of Excitation Brushless without PMG

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 • UAT (Unit Auxiliary Transformer)
• Unit auxiliary transformer is the power transformer that provides power to
auxiliary equipment of a power generating station during its normal operation.
• At Adani Power each unit consists of two unit auxiliary transformers as tapping
are taken with the output of the generator to power various auxiliary systems
inside the plant.

Company Name : ABB

Type: Power Frequency:50Hz

Type Of Cooling: ONAN/ONAF Temp. of oil / windings: 50 / 55 degree C

Rated Current: Insulation to ground:

Step voltage: Control voltage:

Variation : No. of steps:

Nominal power(ONAN/ONAF): Nominal voltage (KV): HV LV

(MVA)
Nominal current (ONAN/ONAF)

Insulation Level

Testing voltage HV LV LVN

Nominal rated 24 7.2 __

Power frequency 50 20 20

Lightning impulse 125 60 60

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• Generation transformers

• Generator step-up transformers are the critical link between the power station
and the transmission network.
• They must be built to withstand extreme thermal loading without ageing
prematurely.
• There transformers are located in a power station and are built as single phase
or three phase units.
• For each phase there are separate GT’s (i.e. R,Y&B)

Company name : ABB

Type: Power Transformer Frequency: 50Hz
Type of cooling : ONAN/ONAF/OFAF Vector Group: YNd11
Top oil temp. rise : 50 deg. C
Main winding temp. rise : 50 deg. C
Nominal HV : 235 Kv LV : 24 kV
voltage:
Nominal power(MVA) Nominal current (A)
ONAN/ONAF/OFAF ONAN/ONAF/OFAF
HV 240/320/400 589.63/786.18/982.72
LV 240/320/400 57773.60/7698/9622.50
Vector Group : YNd11
Tap position HV line voltage(Kv) HV Line Current (A) Tap
Selector
ONAN ONAF OFAF
Connects
1 (MAX) 246.75 561.56 784.74 935.93 2-7
2 240.88 572.25 767.00 958.76 2-6
3(NOR) 235.00 589.63 786.18 982.72 2-5
4 229.13 604.75 806.34 1007.92 2-4
5(MIN) 223.25 620.67 827.56 1034.45 2-3

NOTE: ABOVE TABLE GIVES VOLTAGE AT NO LOAD.

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• Station transformer

• Station transformer is the step down transformer which is generally used in the
generation station.
• Station transformer are used in case of black out in the power plant to start the
plant auxiliaries again.
• We have to put the station transformer in always charged condition.
• There are two station transformers for each unit of the plant.

Type: power Frequency: 50Hz

Type of cooling: ONAN/ONAF Vector Group : YNyn0yn0

Nominal power (MVA) ONAN : 30 ONAF : 50

Nominal voltage (Kv) HV LV1 LV2

22.0 6.9 6.9
Nominal Current (MVA) 50 25 25

On-Load tap changer

Type: EASUN-MR 350Y 123/C 10.19.3W

Rated Current : 350 Amp

VARIATION : +10 % 10 – 10% of HV

No. of steps :16

Step Voltage : 1587.7 V

Control Voltage : 110 V AC

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 PHASE 3 AND PHASE 4

Phase 3:
• Phase 3 has two generation units each of 660MW (i.e. 1320 MW).

Phase 4:
• Phase 4 has three generation units each of 660MW (i.e. 1980 MW).

• Main parts of UNIT 5,6,7,8 & 9 consists of:

Generators
Excitation Transformers
Station Transformers
Generation Transformers
Unit Auxiliary Transformers

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Specifications: noted

• Generator 660MW

Company Name: Dongfang Electric Machinery Ltd.

Rated Capacity : 776.5 MVA Rated Power: 660 MW
Rated Stator Voltage: 22Kv , +/-5% Rated Stator Current : 20377A
Field Current : 4476 A Phase: 3
No. of terminals : 6 Frequency:50 Hz
Power Factor : 0.85lag Rated Speed : 3000 rpm
Wiring Type: Y-Y type (Double Star)
Cooling Method : Water , Hydrogen
Cooling water of stator winding : Directly water cooled
Flow : 102 m3/Hr
Cooling Water Pressure : 0.20 MPa
Cooling of stator core & rotor : Directly Hydrogen Cooled
Insulation Class : F
Excitation : Terminal, self, static excitation
Generating rotating direction : Clock wise
Rated Hydrogen Pressure : 0.45 MPa
Excitation Type: Static Thyristor Excitation
Short Circuit Ratio: >= 0.5
Efficiency: >=98.8 %

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• Unit Auxiliary Transformers

These specifications are same for both PHASE 3 & PHASE 4

Company Name: Shandong Power Equipment CO. (SPECO)

Type of Product: SFZ10-35000/20 TH

Rated Power 35000/35000 kVA

Rated Voltage (22+- 4*1.25%)/6.9 kV

Type of Cooling ONAN / ONAF

Connection Symbol Dyn1

Number of Phase 3

Rated Frequency 50 Hz

Working Condition Outdoors

Noise Level 69.4 dB

Transformer Oil DB-25#

Insulation Level H.V. Line Terminal 200/85 kV

L.V. Line Terminal 60/28 kV

I.V. neutral 60/28 kV

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• Generation Transformers

These specifications are same for both PHASE 3 & PHASE 4

There are separate generation transformers for each phase i.e. R,Y & B .

Company Name : Shandong Power Equipment CO. (SPECO)

Type of Product : DFP-270000/400TH

Rated Power 270000/270000 kVA

Rated Voltage ((420/√3)+-2*2.5%)/22 kV

Type of Cooling ONAN / ONAF / OFAF

Connection Symbol YNd11

Number of Phase 1

Rated Frequency 50 Hz

Working Condition Out Doors

Noise Level 69.4 dB

Transformer Oil DB-25#

Insulation Level H.V. Line Terminal 425/630 kV

L.V. Line Terminal 85/85 kV

I.V. neutral 200/85 kV

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• Station Transformer

Company Name : Shandong Power Equipment CO. (SPECO)

Type of Product : SFFZ-70000/400TH

Rated Power 70000/38000-32000 kVA

Rated Voltage (400+-8*1.25%)/6.9 11.5kV

Type of Cooling ONAN / ONAF

Connection Symbol YNyn0-yn0+d11

Number of Phase 3

Rated Frequency 50 Hz

Working Condition Out Doors

Noise Level 69.4 dB

Transformer Oil DB-25#

Insulation Level H.V. Line Terminal 1300/630 kV

L.V. Line Terminal 60/25 kV

I.V. neutral 75/35 kV

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 The whole Adani Mundra Power Plant Electrical section is divided into 5 main
parts:

• EMD 330
• EMD 660
• EMD SWYRD
• EMD BOP
• EMD CHP
• TESTING

1) EMD 330 and EMD 660

This section is defined as electrical maintenance department for 330 MW and 660
MW respectively.
This section consists of several areas like:
• Switchgears: - In electrical power system, switchgear is composed of electrical
disconnect switches, fuses or circuit breakers used to control, protect and isolate
electrical equipment.
There are two types of switch gears system:

1) LT switchgears – up to 1 KV
It includes low voltage C.B, switches, off load electrical isolators, HRC fuses,
earth leakage C.B, MCB.

2) HT switchgears – above 36 KV

• AHP
In thermal power plants, coal is used as a fuel for generating electricity.
After burning of coal, 40% of total coal consumption is converted into ash which
need to properly disposed – off from the thermal power plant.

Ash handling plant in power plant are used to cooled down the ash to
manageable temperature, transferred to a disposal area or storage which is
further utilized in other industries .
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• ESP

• ESP is defined as electro static precipitator.

• It is a device which removes dust or other finely divided particles from flue gases
by charging the particles inductively with an electric field, then attracting them
to highly charged collector plate. Also known as precipitator. The process
depends on two steps. In the first step the suspension passes through an electric
discharge (corona discharge) area where ionization of the gas occurs. The
charged particles drift towards an electrode of opposite sign and are deposited
on the electrode where their electric charge is neutralized. The phenomenon
would be more correctly designated as electrode position from the gas phase.

Note: -

• There are 20 fields for each ESP: -

A1 – A5 & B1 – B5 [PASS – A]
C1 – C5 & D1 – D5 [PASS –B]
• Each field consist of two hoppers
• Each hopper consists of 3 heaters for heating the deposited coal as there is no
moisture in it.

Ratings for ESP 7: Noted

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• Field control panel for ESP
Rated Voltage 415 V
Rated Current 524 A
Frequency 50Hz

• ESP Transformer: Dry Type Power Transformer

Rated Power 2000 kW
Rated Voltage 6.6 kV
Frequency 50 Hz
Type of Cooling AN/AF

• Hopper Heater
Rated Voltage 415 V AC
Rated Current 160 A
Frequency 50Hz

• Rectifier
Rated Voltage 72 kV
Rated Current 1800 mA

• Important Point:
Between the electrode and the collecting plate there is a hammer type structure
suspended in the ESP which is connected to a motor shaft this hammers the
collecting plate to remove the ash particles collected on the plate and those
particles are collected to the hopper.

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• EMD – CHP (Coal Handling Plant)

• In a thermal power plant, the initial process is ‘Coal Handling’.

• The huge amount of coal is supplied usually through railways.
• A railway siding line is taken into the power station and the coal is delivered
in the storage yard.
• After the coal reaches the storage yard it is transferred to transferring towers
by means of these towers the coal can be transferred further.
• The transfer towers are connected with the help of belt conveyors for
transferring of coal from one tower to other.
• Before reaching the crusher house there are magnetic seperators at
discharge end of the conveyor for removal of remaining metallic substances
from the coal.
• When the coal reaches the crusher house it is broken to desired size of coal
used.
• Then there is a driving house where the motors are installed for the use of
conveyor belts.
• Now the coal is further transferred to the bunker of different units of the
plant by which the coal can be used for the boilers.

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• EMD BOP

This department is called as Balance of Plant

In this there are many more sub departments like:

1. Sea intake pump house:

1.1. Phase 1 & Phase 2
1.2. Phase 3 & Phase 4
2. Sea Water Desalination Plant(RO)
2.1. New 20 MLD
2.2. Old 20 MLD
2.3. 7 MLD
3. Fire Fighting Pump House
4. Comprehensive Pump House
5. Hydrogen generation Unit
6. LPO/HFO Pump House
7. ETP Plant
8. JWWTP & SWWTP (Phase 3 & Phase 4)
9. FGD Plant
10. DM water plant

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DM WATER PLANT

• Demineralization is the process of removing mineral salts from water by using

the ion exchange process.
• Demineralized water is completely free of dissolved minerals

Following processes takes place in this plant are:

• Distillation
• Deionization
• Membrane filtration(RO)
• Electrodyalisis
• Or Other technologies

“Cation exchange resins and anions exchange resins are used for ion-exchange
method”.

Water supply system

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Page | 28
FGD plant

• Flue gas desulfurization (FGD) is a set of technologies used to remove sulfur

dioxide (SO2) from exhaust flue gases of fossil-fuel power plants, and from the
emissions of sulfur oxide emitting processes.
• Flue gas desulfurization plant is installed between the ID Fan of Boiler and the
Chimney.
• This unit includes a booster fan for pumping the flue gases inside. This booster
fan consumes 40MW of power.

Diagram:

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 • EMD SWYRD
After the generation of electricity, the electricity is transferred to the switchyard
area of each phase.
In Adani power mundra there are 4 switchyards
• Phase 1 switchyard
• Phase 2 switchyard
• Phase 3 switchyard
• Phase 4 switchyard
Important points:
Phase 1 switch yard transfer the power from unit 1 and unit 2.
Phase 2 switch yard transfer the power from unit 3 and unit 4.
Phase 3 switch yard transfer the power from unit 5 and unit 6.
Phase 4 switch yard transfer the power from unit 7, unit 8 and unit 9 mainly this is
used to transfer the power for HVDC system.
Phase 1 and Phase 2 switchyard is connected through an ICT known as
interconnecting transformer (specifications given below)
Phase 2, Phase 3 and Phase 4 switchyards are connected through a sectionalizer.
These switch yards are based on 11⁄2 circuit breaker scheme for uninterrupted
power flow.
The switchyard is divided into bays and dias.
A bay consists of: 1) 2 isolators.
2) 1 circuit breaker
3) 2 earth switch
One dia consist of three bays.
So, there are seven dias in each unit switchyard.
CT and PT(CVT) are used to measure the value of current and voltage.

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SF6 circuit breakers are used.
The CT installed is a 5 core CT (4 cores for protection and 1 for measuring).
Various protection schemes are installed in the switchyard for each component.

PHASE 2 - SWITCHYARD

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Internship Assessment

• Teamwork, Planning, Implementation, Correction and some of the qualities that

I attained during the Internship period.

• Skills including hands on experience of Industrial working and functioning

activities improved my theoretical understanding and knowledge drastically.

• The Internship will enable me to decide my future career planning according to

my choice in the vast field of Electrical Engineering and electrical Maintenance.

• The Internship activities carried out made me understand and view all my
theoretical knowledge in actual practice in a working environment.

• All my basics of Engineering and electrical in particular achieved a great boost

from this Internship.

• A great interest has developed in me regarding this field and I look forward to
do my masters in the same.

• It also helped me to clear my vision as any doubts that I had, were immediately
cleared by the Mentor assigned to me for the week.

• I thank all who have helped me improve my skills and engineering knowledge,
particularly the following.

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Conclusion

• Increasing technological advancements are undergoing inside the power plant to

improve the efficiency day-by-day.

• The power sector is a huge and a booming sector where Mechanical Engineers
are a must. Since power requirements are increasing, the production rate should
also meet the demand.

• To meet these demands, the power sector is hiring higher workforce and better
sustainable technologies for future use.

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