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NTPC Summer Training Report 140717175524 Phpapp02 PDF
NTPC Summer Training Report 140717175524 Phpapp02 PDF
NTPC Summer Training Report 140717175524 Phpapp02 PDF
Indias largest power company, NTPC was set up in 1975 to accelerate power
development in India. NTPC is emerging as a diversified power major with presence in
the entire value chain of the power generation business. Apart from power generation,
which is the mainstay of the company, NTPC has already ventured into consultancy,
power trading, ash utilization and coal mining. NTPC ranked 341 st in the 2010, Forbes
Global 2000 ranking of the Worlds biggest companies. NTPC became a Maharatna
company in May, 2010, one of the only four companies to be awarded this status.
The total installed capacity of the company is 39,174 MW (including JVs) with 16 coal
based and 7 gas based stations, located across the country. In addition under JVs, 7
stations are coal based & another station uses naptha/LNG as fuel. The company has set
a target to have an installed power generating capacity of 1,28,000 MW by the year 2032.
The capacity will have a diversified fuel mix comprising 56% coal, 16% Gas, 11%
Nuclear and 17% Renewable Energy Sources(RES) including hydro. By 2032, non-fossil
fuel based generation capacity shall make up nearly 28% of NTPCs portfolio.
NTPC has been operating its plants at high efficiency levels. Although the company has
17.75% of the total national capacity, it contributes 27.40% of total power generation due
to its focus on high efficiency.
1
In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25% as
fresh issue and 5.25% as offer for sale by Government of India. NTPC thus became a
listed company in November 2004 with the Government holding 89.5% of the equity
share capital. In February 2010, the Shareholding of Government of India was reduced
from 89.5% to 84.5% through Further Public Offer. The rest is held by Institutional
Investors and the Public.
2
Strategies of NTPC
Technological Initiatives
3
Corporate Social Responsibility
Environment management
All stations of NTPC are ISO 14001 certified.
Various groups to care of environmental issues.
The Environment Management Group.
Ash tilization Division.
Afforestation Group.
Centre for Power Efficiency & Environment Protection.
Group on Clean Development Mechanism.
NTPC is the second largest owner of trees in the country after the
Forest department
4
Vision
To be the worlds largest and best power producer, powering Indias growth.
Mission
Develop and provide reliable power, related products and services at competitive
prices, integrating multiple energy sources with innovative and eco-friendly
technologies and contribute to society.
B Business Ethics
C Customer Focus
E Enterprising
D Devoted
5
JOURNEY OF NTPC
6
NTPC Environment Policy
"Centre for Power Efficiency and Environment Protection- CENPEE" has been
established in NTPC with the assistance of United States Agency for International
Development- USAID. CENPEEP is efficiency oriented, eco-friendly and eco-nurturing
initiative - a symbol of NTPC's concern towards environmental protection and continued
commitment to sustainable power development in India. As a responsible corporate
citizen, NTPC is making constant efforts to improve the socio-economic status of
the people affected by its projects. Through its Rehabilitation and Resettlement
programmes, the company endeavors to improve the overall socio economic status
Project Affected Persons. NTPC was among the first Public Sector Enterprises to enter
into a Memorandum of Understanding-MOU with the Government in 1987-88. NTPC
has been placed under the 'Excellent category' (the best category) every year since the
MOU system became operative. Harmony between man and environment is the essence
of healthy life and growth. Therefore, maintenance of ecological balance and a pristine
environment has been of utmost importance to NTPC. It has been taking
various measures discussed below for mitigation of environment pollution due to power
generation.
NTPC is the second largest owner of trees in the country after the Forest department.
7
As early as in November 1995, NTPC brought out a comprehensive document entitled
"NTPC Environment Policy and Environment Management System". Amongst the
guiding principles adopted in the document is companys proactive approach to
environment, optimum utilization of equipment, adoption of latest technologies and
continual environment improvement. The policy also envisages efficient utilization of
resources, thereby minimizing waste, maximizing ash utilization and providing green belt
all around the plant for maintaining ecological balance.
Electrostatic Precipitators:
The ash left behind after combustion of coal is arrested in high efficiency Electrostatic
Precipitators (ESPs) and particulate emission is controlled well within the stipulated
norms. The ash collected in the ESPs is disposed to Ash Ponds in slurry form.
8
Flue Gas Stacks:
Tall Flue Gas Stacks have been provided for wide dispersion of the gaseous emissions
(SOX, NOX etc.) into the atmosphere.
Low-NOX Burners:
In gas based NTPC power stations, NOX emissions are controlled by provision of Low-
NOX Burners (Dry or wet type) and in coal fired stations, by adopting best combustion
practices.
Neutralization Pits:
Neutralization pits have been provided in the Water Treatment Plant (WTP) for pH
correction of the Effluents before discharge into Effluent Treatment Plant (ETP) for
further treatment and use.
DE & DS Systems:
Dust Extraction (DE) and Dust Suppression (DS) systems have been installed in all coal
fired power stations in NTPC to contain and extract the fugitive dust released in the Coal
Handling Plant (CHP).
Cooling Towers:
Cooling Towers have been provided for cooling the hot Condenser cooling water in
closed cycle, Condenser Cooling Water (CCW) Systems. This helps in reduction in
thermal pollution and conservation of fresh water.
9
Ash Dykes & Ash Disposal systems:
Ash ponds have been provided at all coal based stations except Dadri where Dry Ash
Disposal System has been provided. Ash Ponds have been divided into lagoons and
provided with garlanding arrangement for changeover of the ash slurry feed points for
even filling of the pond and for effective settlement of the ash particles.
Ash in slurry form is discharged into the lagoons where ash particles get settled from the
slurry and clear effluent water is discharged from the ash pond. The discharged effluents
conform to standards specified by CPCB and the same is regularly monitored.
At its Dadri Power Station, NTPC has set up a unique system for dry ash collection and
disposal facility with Ash Mound formation. This has been envisaged for the first time in
Asia which has resulted in progressive development of green belt besides far less
requirement of land and less water requirement as compared to the wet ash disposal
system.
10
Liquid Waste Treatment Plants & Management System:
The objective of industrial liquid effluent treatment plant (ETP) is to discharge lesser and
cleaner effluent from the power plants to meet environmental regulations. After primary
treatment at the source of their generation, the effluents are sent to the ETP for further
treatment. The composite liquid effluent treatment plant has been designed to treat all
liquid effluents which originate within the power station e.g. Water Treatment Plant
(WTP), Condensate Polishing Unit (CPU) effluent, Coal Handling Plant (CHP) effluent,
floor washings, service water drains etc. The scheme involves collection of various
effluents and their appropriate treatment centrally and re-circulation of the treated
effluent for various plant uses.
NTPC has implemented such systems in a number of its power stations such as
Ramagundam, Simhadri, Kayamkulam, Singrauli, Rihand, Vindhyachal, Korba, Jhanor
Gandhar, Faridabad, Farakka, Kahalgaon and Talcher Kaniha. These plants have helped
to control quality and quantity of the effluents discharged from the stations.
11
ABOUT BTPS
BADARPUR THERMAL POWER STATION was established on 1973 and it was the
part of Central Government. On 01/04/1978 is was given as No Loss No Profit Plant of
NTPC. Since then operating performance of NTPC has been considerably above the
national average. The availability factor for coal stations has increased from 85.03 % in
1997-98 to 90.09 % in 2006-07, which compares favorably with international standards.
The PLF has increased from 75.2% in1997-98 to 89.4% during the year 2006-07 which is
the highest since the inception of NTPC.
Badarpur thermal power station started with a single 95 mw unit. There were 2 more units
(95 MW each) installed in next 2 consecutive years. Now it has total five units with total capacity of
720 MW. Ownership of BTPS was transferred to NTPC with effect from 01.06.2006 through
GOIs Gazette Notification .
The power is supplied to a 220 KV network that is a part of the northern grid. The ten
circuits through which the power is evacuated from the plant are:
1. Mehrauli
2. Okhla
3. Ballabgarh
4. Indraprastha
5. UP (Noida)
6. Jaipur
12
Given below are the details of unit with the year theyre installed.
13
Station Location
Badarpur is situated only 20 km away from Delhi. The plant is located on the left side of the National
Highway (Delhi-Mathura Road) and it comprises of 430 hectares (678 acres) bordered by the Agra
Canal from East and by Mathura-Delhi Road from West. However, the area for ash
disposal is done in the Delhi Municipal limit and is maintained with the help of Delhi Development
Authority. The plant is also close to the project of 220 kv Double Circuit Transmission line between the
I.P. station and Ballabgarh Cooling Water is obtained from Agra Canal for the cooling
system. Additional 60 cusecs channel has also been constructed parallel to the Agra
Canal so as to obtain uninterrupted water supply during the slit removing operation in
Agra Canal.
14
OPERATION OF A POWER PLANT
Basic Principle
As per FARADAYs Law-Whenever the amount of magnetic flux linked with a circuit
changes, an EMF is produced in the circuit. Generator works on the principle of
producing electricity. To change the flux in the generator turbine is moved in a great
speed with steam. To produce steam, water is heated in the boilers by burning the coal.
In a Badarpur Thermal PowerStation, steam is produced and used to spin a turbine that
operates a generator. Water is heated, turns into steam and spins a steam turbine which
drives an electrical generator. After it passes through the turbine, the steam is condensed
in a condenser; this is known as a Rankine cycle.
The electricity generated at the plant is sent to consumers through high-voltage power
lines The Badarpur Thermal Power Plant has Steam Turbine-Driven Generators which
has a collective capacity of 705MW. The fuel being used is Coal which is supplied from
the Jharia Coal Field in Jharkhand. Water supply is given from the Agra Canal.
15
Basic Steps of Electricity Generation
The basic steps in the generation of electricity from coal involves following steps:
Coal to steam
Steam to mechanical power
Mechanical power to electrical power
16
Coal to Electricity : Basics
17
18
19
PARTS OF A POWER PLANT
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12. Deaerator
13. Feed heater
14. Coal conveyor
15. Coal hopper
16. Pulverised fuel mill
17. Boiler drum
18. Ash hopper
19. Super heater
20. Forced draught fan
21. Reheater
22. Air intake
23. Economiser
24. Air preheater
25. Precipitator
26. Induced draught fan
27. Flue Gas
1. Cooling Tower
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove process
heat and cool the working fluid to near the wet-bulb air temperature or in the case of
closed circuit dry cooling towers rely solely on air to cool the working fluid to near the
dry-bulb air temperature. Common applications include cooling the circulating water
used in oil refineries, chemical plants, power stations and building cooling.
The towers vary in size from small roof-top units to very large hyperboloid structures that
can be up to 200 meters tall and 100 meters in diameter, or rectangular structures that can
be over 40 meters tall and 80 meters long. Smaller towers are normally factory-built,
while larger ones are constructed on site. The absorbed heat is rejected to the atmosphere
by the evaporation of some of the cooling water in mechanical forced-draft or induced
21
Draft towers or in natural draft hyperbolic shaped cooling towers as seen at most nuclear
power plants.
22
neutral voltage. Another system commonly seen in North America is to have a delta
connected secondary with a center tap on one of the windings supplying the ground and
neutral.
This allows for 240 V three phase as well as three different single phase voltages( 120 V
between two of the phases and neutral , 208 V between the third phase ( or wild leg) and
neutral and 240 V between any two phase) to be available from the same supply.
5. Electrical generator
An Electrical generator is a device that converts kinetic energy to electrical energy,
generally using electromagnetic induction. The task of converting the electrical energy
into mechanical energy is accomplished by using a motor. The source of mechanical
energy maybe water falling through the turbine or steam turning a turbine (as is the case
with thermal power plants). There are several classifications for modern steam turbines.
Steam turbines are used in our entire major coal fired power stations to drive the
generators or alternators, which produce electricity. The turbines themselves are driven
by steam generated in "boilers or "steam generators" as they are sometimes called.
Electrical power stations use large steam turbines driving electric generators to produce
most (about 86%) of the worlds electricity. These centralized stations are of two types:
fossil fuel power plants and nuclear power plants. The turbines used for electric power
generation are most often directly coupled to their-generators .As the generators must
rotate at constant synchronous speeds according to the frequency of the electric power
system, the most common speeds are 3000 r/min for 50 Hz systems, and 3600 r/min for
60 Hz systems. Most large nuclear sets rotate at half those speeds, and have a 4-pole
generator rather than the more common 2-pole one.
23
rotating blades. The rotating blades convert the kinetic energy into impulse and reaction
forces, caused by pressure drop, which results in the rotation of the turbine shaft. The
turbine shaft is connected to a generator, which produces the electrical energy.
Low Pressure Turbine (LPT) consists of 4x2 stages. After passing through Intermediate
Pressure Turbine steam is passed through LPT which is made up of two parts- LPC
REAR & LPC FRONT. As water gets cooler here it gathers into a HOTWELL placed in
lower parts of turbine.
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8. Condenser
The steam coming out from the Low Pressure Turbine (a little above its boiling pump) is
brought into thermal contact with cold water (pumped in from the cooling tower) in the
condenser, where it condenses rapidly back into water, creating near Vacuum-like
conditions inside the condenser chest.
25
process variable whose value is provided by sensors that monitor changes in such
conditions. The opening or closing of control valves is done by means of electrical,
hydraulic or pneumatic systems.
12. Deaerator
A Deaerator is a device for air removal and used to remove dissolved gases (an alternate
would be the use of water treatment chemicals) from boiler feed water to make it non-
corrosive. A dearator typically includes a vertical domed deaeration section as the
deaeration boiler feed water tank. A Steam generating boiler requires that the circulating
steam, condensate, and feed water should be devoid of dissolved gases, particularly
corrosive ones and dissolved or suspended solids. The gases will give rise to corrosion of
the metal. The solids will deposit on the heating surfaces giving rise to localized heating
and tube ruptures due to overheating. Under some conditions it may give rise to stress
corrosion cracking. Deaerator level and pressure must be controlled by adjusting control
valves the level by regulating condensate flow and the pressure by regulating steam flow.
If operated properly, most deaerator vendors will guarantee that oxygen in the deaerated
water will not exceed 7 ppb by weight (0.005 cm3/L)
26
metal when the feed water is introduced back into the steam cycle. In a steam power
(usually modelled as a modified Rankine cycle), feed water heaters allow the feed water
to be brought up to the saturation temperature very gradually. This minimizes the
inevitable irreversibility associated with heat transfer to the working fluid (water).
27
stainless) and its working involve temperature of 390C and pressure well above 350psi
(2.4MPa). The separated steam is drawn out from the top section of the drum.
Saturated steam is drawn off the top of the drum. The steam will re-enter the furnace in
through a super heater, while the saturated water at the bottom of steam drum flows down
to the mud-drum /feed water drum by down comer tubes accessories include a safety
valve, water level indicator and fuse plug.
21. Reheater
Reheater is a heater which is used to raise the temperature of steam which has fallen from
the intermediate pressure turbine.
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22. Air Intake
Air is taken from the environment by an air intake tower which is fed to the fuel.
23. Economizers
Economizer, or in the UK economizer, are mechanical devices intended to reduce energy
consumption, or to perform another useful function like preheating a fluid. The term
economizer is used for other purposes as well-Boiler, power plant, heating, ventilating
and air-conditioning. In boilers, economizer are heat exchange devices that heat fluids ,
usually water, up to but not normally beyond the boiling point of the fluid. Economizers
are so named because they can make use of the enthalpy and improving the boilers
efficiency. They are devices fitted to a boiler which save energy by using the exhaust
gases from the boiler to preheat the cold water used to fill it (the feed water). Modern day
boilers, such as those in cold fired power stations, are still fitted with economizer which
is decedents of Greens original design. In this context there are turbines before it is
pumped to the boilers. A common application of economizer in steam power plants is to
capture the waste heat from boiler stack gases (flue gas) and transfer thus it to the boiler
feed water thus lowering the needed energy input , in turn reducing the firing rates to
accomplish the rated boiler output . Economizer lower stack temperatures which may
cause condensation of acidic combustion gases and serious equipment corrosion damage
if care is not taken in their design and material selection.
29
25. Precipitator
An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that
removes particles from a flowing gas (such as air) using the force of an induced
electrostatic charge. Electrostatic precipitators are highly efficient filtration devices, and
can easily remove fine particulate matter such as dust and smoke from the air steam.
ESPs continue to be excellent devices for control of many industrial particulate
emissions, including smoke from electricity-generating utilities (coal and oil fired), salt
cake collection from black liquor boilers in pump mills, and catalyst collection from
fluidized bed catalytic crackers from several hundred thousand ACFM in the largest coal-
fired boiler applications. The original parallel plate-Weighted wire design (described
above) has evolved as more efficient (and robust) discharge electrode designs, today
focus is on rigid discharge electrodes to which many sharpened spikes are attached ,
maximizing corona production. Transformer rectifier systems apply voltages of
50-100 Kilovolts at relatively high current densities. Modern controls minimize sparking
and prevent arcing, avoiding damage to the components. Automatic rapping systems and
hopper evacuation systems remove the collected particulate matter while on line allowing
ESPs to stay in operation for years at a time.
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device. Flue gas is usually composed of carbon dioxide (CO2) and water vapour as well
as nitrogen and excess oxygen remaining from the intake combustion air. It also contains
a small percentage of pollutants such as particulates matter, carbon mono oxide, nitrogen
oxides and sulphur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300
feet) or more, so as to disperse the exhaust pollutants over a greater area and thereby
reduce the concentration of the pollutants to the levels required by government's
environmental policies and regulations. The flue gases are exhausted from stoves, ovens,
fireplaces or other small sources within residential abodes, restaurants, hotels through
other stacks which are referred to as chimneys.
31
VARIOUS CYCLES AT POWER STATION
32
PRIMARY AIR CYCLE
P A FAN
PULVERISER
33
SECONDARY AIR CYCLE
W
I
FD FAN IGNITER FAN N
D
B
SCANNER AIR FAN O
SCAPH
X
SCANNER COOLING
APH
WIND BOX
BOILER
34
ELECTRICITY CYCLE
GENERATOR
UAT UAT
To Auxiliaries
To Auxiliaries
MAIN TRANSFORMER
SWITCH YARD
OUTGOING FEEDER
35
CONDENSATE CYCLE
HOT WELL
CONDENSATE PUMPS
MAIN EJECTOR
LP HEATER 2
LP HEATER 3
LP HEATER 4
DEAERATOR
BOILER
36 FEED PUMP
FEED WATER CYCLE
HP HEATOR 5
HP HEATOR 6
HP HEATOR 7
ECONOMISER
BOILER DRUM
DOWN COMERS
UPRISERS
BOILER DRUM
37
STEAM CYCLE
BOILER DRUM
L.T.S.H.
FLATEN S.H.
FINAL S.H.
H P TURBINE
C.R.H.
H.R.H
I P TURBINE
L P TURBINE
CONDENSER
38
Coal Cycle
39
Flue Gas Cycle
40
ELECTRICAL MAINTENANCE DEPARTMENT I (EMD-I)
I was assigned to do training in this division from 11th June to 29th June.
41
MOTORS
In modern thermal power plant three phase squirrel cage induction motors are used but
sometime double wound motor is used when we need high starting torque e.g. in ball mill.
Ns (speed) =120f/p
Stator can handle concentrated single layer winding, with each coil occupying one stator slot
The most common type of winding are:
1. DISTRIBUTEDWINDING:
This type of winding is distributed over a number of slots.
2. DOUBLELAYERWINDING:
Each stator slot contains sides of two different coils.
Squirrel cage and wound cage have same mode of operation. Rotor conductors cut the
rotating stator magnetic field. an emf is induced across the rotor winding, current flows,
a rotor magnetic field is produced which interacts with the stator field causing a turning
42
motion. The rotor does not rotate at synchronous speed, its speed varies with applied
load. The slip speed being just enough to enable sufficient induced rotor current to produce the power
dissipated by the motor load and motor losses.
A good bearing is needed for trouble free operation of motor. Since it is very costly part of the motor,
due care has to be taken by checking it at regular intervals. So lubricating plays an
important role. Two types of lubricating are widely used
1. Oil lubrication
2. Grease lubrication
3. Insulation
INSULATION
Winding is an essential part so it should be insulated. Following types of insulation are widely used
TYPES OF INSULATION
Y 90
A 105
E 120
B 130
F 155
H 180
C more than 180
5. IGNITOR FAN
It supplies air for cooling of igniters.
INSTRUMENTS SEEN
1. MICROMETER
This instrument is used for measuring inside as well as outside diameter of bearing.
2. MEGGAR
This instrument is used for measuring insulation resistance.
3. VIBRATION TESTER
It measures the vibration of the motor. It is measured in three dimensions-axial, vertical and
horizontal.
44
SWITCH GEAR
INTRODUCTION
Switchgear is one that makes or breaks the electrical circuit. It is a switching device that opens& closes a
circuit that defined as apparatus used for switching, Lon rolling & protecting the electrical
circuit & equipments. The switchgear equipment is essentially concerned with switching & interrupting
currents either under normal or abnormal operating conditions. The tubular switch with ordinary
fuse is simplest form of switchgear & is used to control & protect& other equipments in
homes, offices etc. For circuits of higher ratings, a High Rupturing Capacity (H.R.C) fuse in
condition with a switch may serve the purpose of controlling &protecting the circuit. However
such switchgear cannot be used profitably on high voltage system (3.3 KV) for 2 reasons. Firstly, when a
fuse blows, it takes some time to replace it &consequently there is interruption of service to
customer. Secondly, the fuse cannot successfully interrupt large currents that result from
the High Voltage System. In order to interrupt heavy fault currents, automatic circuit
breakers are used. There are very few types of circuit breakers in B.P.T.S they are VCB, OCB, and
SF6 gas circuit breaker. The most expensive circuit breaker is the SF6 type due to gas. There
are various companies which manufacture these circuit breakers: VOLTAS, JYOTI, and
KIRLOSKAR. Switchgear includes switches, fuses, circuit breakers, relays & other equipments
45
THE EQUIPMENTS THAT NORMALLY FALL IN THIS CATEGORY ARE:-
1. ISOLATOR
An isolator is one that can break the electrical circuit when the circuit is to be switched on no load.
These are used in various circuits for isolating the certain portion when required for
maintenance etc. An operating mechanism box normally installed at ground level drives the isolator.
The box has an operating mechanism in addition to its contactor circuit and auxiliary contacts may be
solenoid operated pneumatic three phase motor or DC motor transmitting through a spur gear to
the torsion shaft of the isolator. Certain interlocks are also provided with the isolator
These are
1. Isolator cannot operate unless breaker is open
2. Bus 1 and bus 2 isolators cannot be closed simultaneously
3. The interlock can be bypass in the event of closing of bus coupler breaker.
4. No isolator can operate when the corresponding earth switch is on
2. SWITCHING ISOLATOR
Switching isolator is capable of:
1. Interrupting charging current
2. Interrupting transformer magnetizing current
3. Load transformer switching. Its main application is in connection with the
transformer feeder as the unit makes it possible to switch gear one transformer
while the other is still on load.
3. CIRCUIT BREAKER
One which can make or break the circuit on load and even on faults is referred to as circuit
breakers. This equipment is the most important and is heavy duty equipment mainly utilized for
protection of various circuits and operations on load. Normally circuit breakers
installed are accompanied by isolators.
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4. LOAD BREAK SWITCHES
These are those interrupting devices which can make or break circuits. These are normally on same
circuit, which are backed by circuit breakers
5. EARTH SWITCHES
Devices which are used normally to earth a particular system, to avoid any accident
happening due to induction on account of live adjoining circuits. These equipments do not handle
any appreciable current at all. Apart from this equipment there are a number of relays
etc. which are used in switchgear.
LT SWITCHGEAR
In LT switchgear there is no interlocking. It is classified in following ways:-
1. MAIN SWITCH
Main switch is control equipment which controls or disconnects the main supply. The
main switch for 3 phase supply is available for the range 32A, 63A, 100A, 200Q,
300A at 500V grade.
2. FUSES
With Avery high generating capacity of the modern power stations extremely heavy
carnets would flow in the fault and the fuse clearing the fault would be required to
withstand extremely heavy stress in process. It is used for supplying power to
auxiliaries with backup fuse protection. With fuses, quick break, quick make and
double break switch fuses for 63A and 100A, switch fuses for 200A,400A, 600A,
800A and 1000A are used.
3. CONTACTORS
AC Contractors are 3 poles suitable for D.O.L Starting of motors and protecting the
connected motors.
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4. OVERLOAD RELAY
For overload protection, thermal overload relay are best suited for this purpose. They
operate due to the action of heat generated by passage of current through relay element.
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HT SWITCHGEAR
Type-HKH 12/1000c
Rated Voltage-66 KV
Normal Current-1250A
Frequency-5Hz
Breaking Capacity-3.4+KA Symmetrical
3.4+KA Asymmetrical
360 MVA Symmetrical
Motor Voltage-220 V/DC
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2. AIR CIRCUIT BREAKER
In this the compressed air pressure around 15 kg per cm^2 is used for extinction of arc
caused by flow of air around the moving circuit . The breaker is closed by applying
pressure at lower opening and opened by applying pressure at upper opening. When
contacts operate, the cold air rushes around the movable contacts and blown the arc:
It has the following advantages over OCB:-
i. Fire hazard due to oil are eliminated.
ii. Operation takes place quickly.
iii. There is less burning of contacts since the duration is short and consistent.
iv. Facility for frequent operation since the cooling medium is replaced
constantly.
Rated Voltage-6.6 KV
Current-630 A
Auxiliary current-220 V/DC
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3. SF6 CIRCUIT BREAKER
This type of circuit breaker is of construction to dead tank bulk oil to circuit breaker but
the principle of current interruption is similar to that of air blast circuit breaker. It simply
employs the arc extinguishing medium namely SF6. When it is broken down under an
electrical stress, it will quickly reconstitute itself.
Circuit Breakers-HPA
Standard-1 EC 56
Rated Voltage-12 KV
Insulation Level-28/75 KV
Rated Frequency-50 Hz
Breaking Current-40 KA
Rated Current-1600 A
Making Capacity-110 KA
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4. VACUUM CIRCUIT BREAKER
It works on the principle that vacuum is used to save the purpose of insulation and. In
regards of insulation and strength, vacuum is superior dielectric medium and is better
that all other medium except air and sulphur which are generally used at high pressure.
Rated frequency-50 Hz
Rated making Current-10 Peak KA
Rated Voltage-12 KV
Supply Voltage Closing-220 V/DC
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COAL HANDLING PLANT (CHP)
COALSUPPLIEDAT BTPS
Coal is supplied to BTPS by Jharia coal mines. It is non-cooking coal and has following
specifications:-
Moisture- less than 8%
Volatile matter-17% to 19%
Ash- 35% - 40%
Calorific Value- 4500 to 5300 Kcal/kg
Coal is received in railway box racks containing 20 - 42 wagons in each rack.
Capacity of each box wagon is about 55 ton.
These wagons are placed on 2 wagon tippler in OCHP & one wagon tippler in
NCHP, in total 3, capacity 80 ton each.
53
COAL CYCLE
54
OLD COAL HANDLING PLANT (OCHP)
KEY DIAGRAM
55
The main constituents of OCHP plant are:-
WAGON TIPPLER
Wagon from coal yard come to the tippler and emptied here. There are 2 wagon tipplers
in the OCHP. The tippler is tilted to about 137- 141 so that coal from the wagon is
emptied into the hopper. Elliptics feeder is used in OCHP. Total 8 feeders are used, 4 in
each hopper.
Slip Ring Induction Motor is used to operate a wagon tippler. This type of IM is used in
the tippler because of its high resistance, low speed & high torque characteristics. The
rating of the motor used is:
o Power 55 Kw
o Voltage 415V
o Current 102A
o Speed 1480rpm
o Phase 3
o Frequency 50Hz
a) ROTASIDE: - It is used for open type wagons in which each wagon carries around 50-
56 tons of coal. The wagon is tilted by 150 to put the coal in the unloading hopper.
b) ROTARY: - In this case the unloading hopper is placed directly under the tippler table.
This is also used to tilt the wagon tippler to 180.
c) ROCKING TYPE: - It is used for close type wagons. In this hoppers is placed by the
side of end rocking is provided to facilitate unloading of coal at corners of the wagon.
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CONVEYER
Conveyer belts are used in the OCHP to transfer coal from one place to other as required
in a convenient & safe way. All the belts are numbered accordingly so that their function can be easily
demarcated. These belts are made of rubber & move with a speed of 250-300 m/min.
Motor employed for the conveyer has a capacity of 150 HP. These conveyers have a capacity of
carrying the coal at the rate of 400 ton/hr.
METAL DETECTOR
As the conveyer belt take coal from wagon to crusher house, no metal piece should go
along with coal. To achieve this objective, metal detectors & separators are used. In the
OCHP, these MDs are installed in the conveyer belts 2A & 2B.
CRUSHER HOUSE
Both the plants i.e. OCHP & NCHP use TATA crusher powered by BHEL motor.
Crusher is of ring type and the motor is a HT motor of rating 400HP & 6.6 KV. Crusher is designed to
crush the pieces to 20 mm size i.e. practically considered as the optimum size for transfer
via conveyer.
ROTARY BREAKER
If any large piece of metal of any hard substances like metal impurities comes in the conveyer belt which
cause load on the metal separator, then the rotary breaker rejects them reducing the load on the metal
detector.
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STACKER-CUM-RECLAIMER
It is used for stacking & reclaiming the coal from the stockyard in case of unavailability
of wagons from coal mines.
PLOUGH FEEDER
These plough feeders are generally installed under slot bunkers or hoppers. These are used top lough the
coal to the belt from the coal fed from stockyard. These feeders used in this power station
are generally of rotary type.
TRIPPERS
Trippers are provided in the conveyer to collect the material at desired location on either side or along the
conveyer with the help of chute/ducts fitted with tripper itself. The motor in the tripper can make it move
both in forward and reverse direction.
INTERLOCKS: -
The CHP is normally spread over a wide area with centralized control room. Elaborate
scheme is therefore provided. If due to any emergency either the conveyor belt or the motor has to be
stopped, due to this interlocking all the other motors connected to it will automatically
stop &will not work till signal is given from the control room.
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The control & protection scheme normally includes: -
A hooter system to warn that the plant is going to be started. The plant can be
started only after a definite time after the hooter is energized.
Sequential starting of conveyor system and tripping of all proceeding system if
any equipment in the chain is tripped.
Tripping of conveyor from speed switch for protection against belt slippage.
SEQUENTIALOPERATIONOFOCHP:-
b) This coal is tippled into hoppers. If the coal is oversized (400 mm sq), then it is
broken manually so that it passes the hopper mesh where through elliptic feeder it is put into
vibrators & then to conveyor belt 1A & 1B.
c) The coal through conveyor belts 1A & 1B goes to the crusher house. Also the
extra coal is sent to stockyard through these belts.
d) In the crusher house the small size coal pieces goes directly to the belt 2A & 2B whereas the
big size coal pieces are crushed in the crusher & then given to the belts 2A & 2B.
e) The crushed coal is taken to the bunker house via the conveyor belts 3A & 3B where it can be
used for further operations.
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NEW COAL HNDLING PLANT (NCHP)
KEY DIAGRAM
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The main constituents of NCHP plant are:-
Most of the constituents of the NCHP are the same as that of OCHP.
WAGON TIPPLER
In NCHP there is only one wagon tippler. In this it takes 52 sec to raise a wagon, 10 sec to empty the
wagon completely & then again 52 sec to bring the tippler down. A semicircular huge WT gear is used
to run the tippler. Protocol cameras have been installed for safety to ensure that no moving
creature or object is near the wagon which is on the tippler.
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COAL FEEDER TO THE PLANT
Vibro feeders are installed below the hopper which helps in putting the coal to the conveyor belts. There
are 2 conveyor belts & 3 vibro feeder per plant, so in total there are 6 vibrofeeders.
Power 15HP
Voltage 415V
Speed 1450rpm
REJECTION HOUSE
The coal comes to breaker house via conveyor belts 12A & 12B. Now in the breaker house the huge
stones & metal impurities are separated & sent to reject bin house through belts 18A
&18B.
RECLAIM HOPPER
It is the stockyard in which coal is stored for emergency purposes. Around 3 lakh ton of
coal can be stored in it
TURNING POINT 7
CRUSHER HOUSE
To ensure that the coal is of uniform size it is passed through crusher. The crusher is of ring
type. Has a motor rating of 400HP,606KV.It is designed to crush the pieces to 20mm size
EXIT
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SEQUENTIAL OPERATION OF NCHP:-
b) if the coal is oversized (400mm sq), then it is broken manually so that it passes through
the hopper mesh.
d) Conveyors 12A & 12B take the coal to the breaker house which renders the coal size to be 100 mm
sq.
e) Metal separator & metal detector are installed in conveyor belts 14A/B & 15A/B respectively to
remove the metal impurities
.f) Stones which are not able to pass through the 100mm sq mesh of hammer are rejected
via 18A & 18B to the rejection house.
g) Extra coal is sent to the reclaim hopper via conveyor 16A & 16B.
h)From TP-7, coal is taken by conveyor 14A & 14B to the crusher house whose function
is to render size of the coal to 20mm sq.
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V. Belt Feeder: - 15Kw, 180L, 1445rpm
VI. Reversible Belt Feeder: - 18.7Kw, 200L, 1485rp
VII. VF 1-6: - 7.5Kw, 160m, 1485rpm
VIII. VF 7-8: - 15Kw, 180L, 1485rpm
IX. VF 9-12: - 11Kw,160L, 1485rpm
X. WSP Crusher House: - 15Kw, 160m, 4000rpm
XI. WSP Breaker House: - 7.5Kw, 132m, 1865rpm
XII. Metal Separator: - 5KV, 132m, 1410rpm
XIII. Spray Precipitator: - 18.5Kw, 200L, 3000rpm
Sometimes the belt is wet due to any reason, so it may not run due to reduced friction. A
switch senses this and prevents the belt from choking.
Sometime any accident may occur which requires the belt to stop, the pull cords are
pulled to stop the conveyor. This system starts again only when the pull cords are rest.
There is a push button in the control room from where the belt can be stopped in case
of emergency stoppage. Other equipments are pulley. Pulleys are made of mild steel,
rubber logging is provided to increase the friction factor between the pulley and belt.
MILLING SYSTEM
1. RCBUNKER
Raw coal is fed directly to these bunkers. These are 3 in no. per boiler. 4 & tons of coal
are fed in 1 hr. the depth of bunkers is 10m.
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2. RC FEEDER
It transports pre-crust coal from raw coal bunker to mill. The quantity of raw coal
fed in mill can be controlled by speed control of aviator drive controlling damper
and aviator change
3. BALLMILL:
The ball mill crushes the raw coal to a certain height and then allows it to fall
down. Due to impact of ball on coal and attraction as per the particles move over
each other as well as over the Armor lines, the coal gets crushed. Large particles
are broken by impact and full grinding is done by attraction. The Drying and
grinding option takes place simultaneously inside the mill. In ball mill coal is
converted to powdered form and due to pneumatic action the powdered form of
coal is transferred upwards.
4. CLASSIFIER:
It is equipment which serves separation of fine pulverized coal particles medium from
coarse medium. The pulverized coal along with the carrying medium strikes the
impact plate through the lower part. Large particles are then transferred to the ball mill.
5. MILL FAN
From ball mill the powdered coal is sucked through mill fan.
6. CYCLONE SEPARATORS
It separates the pulverized coal from carrying medium. The mixture of pulverized coal
vapour caters the cyclone separators tangentially in the upper part of the separator. Due
to decrease in the velocity the centrifugal action, the pulverized coal separated from the
vapour &falls down to the lower epical part.
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7. THE TURNIGATE
It serves to transport pulverized coal from cyclone separators to pulverized coal bunker or
to worm conveyors. There are 4 turnigates per boiler.
8. WORMCONVEYOR
It is equipment used to distribute the pulverized coal from bunker of one system to
bunker of other system. It can be operated in both directions
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ELECTRICAL MAINTENANCE DEPARTMENT II (EMD-II)
I was assigned to do training in this division from 2nd July to 13th July.
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GENERATORS
The generator works on the principle of electromagnetic induction. There are two
components stator and rotor. The rotor is the moving part and the stator is the stationary
part. The rotor, which has a field winding, is given a excitation through a set of 3000rpm
to give the required frequency of HZ. The rotor is cooled by Hydrogen gas, which is locally
manufactured by the plant and has high heat carrying capacity of low density. If oxygen
and hydrogen get mixed then they will form very high explosive and to prevent their combining in any
way there is seal oil system. The stator cooling is done by de-mineralized (DM) water through hollow
conductors. Water is fed by one end by Teflon tube. A boiler and a turbine are coupled to electric
generators. Steam from the boiler is fed to the turbine through the connecting pipe. Steam
drives the turbine rotor. The turbine rotor drives the generator rotor which turns the
electromagnet within the coil of wire conductors.
Carbon dioxide is provided from the top and oil is provided from bottom to the generator.
With the help of carbon dioxide the oil is drained out to the oil tank.
RATINGSOFTHE GENERATORSUSED
The 100 MW generator generates 10.75 KV and 210 MW generates 15.75 KV. The
voltage is stepped up to 220 KV with the help of generator transformer and is connected to the grid.
The voltage is stepped down to 6.6 KV with the help of UNIT AUXILLARY TRANSFORMER
(UAT) and this voltage is used to drive the HT motors. The voltage is further stepped
down to 415 V and then to 220 V and this voltage is used to drive Lt Motors.
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TURBOGENERATOR100MW
POWER 210,000 KW
FREQUENCY 50 HZ
EXCITATION 310 V
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TRANSFORMERS
INTRODUCTION
It is a static machine which increases or decreases the AC voltage without changing the
frequency of the supply.
It is a device that:
Transfer electric power from one circuit to another.
It accomplishes this by electromagnetic induction.
In this the two electric circuits are in mutual inductive influence of each other.
WORKING PRINCIPLE:
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MAIN PARTS
CONSERVATOR
It is used generally to conserve the insulating property of the oil from deterioration&
protect the transformer against failure on account of bad quality of oil.
BUSHINGS
It is made from highly insulating material to insulate & to bring out the terminals
of the transformer from the container. The bushings are of 3 types:
OIL GUAGE
Every transformer with an oil guage to indicate the oil level. The oil guage may be
provided with the alarm contacts which gave an alarm the oil level has dropped
beyond permissible height due to oil leak etc.
TAPPINGS
The transformer are usually provided with few tappings on secondary side so
that output voltage can be varied for constant input voltage.
RADIATORS
It increases the surface area of the tank & more heat is thus radiated in less time.
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CONSTRUCTIONAL FEATURES:
CLASSIFICATION:
a) 1phase transformer
b) 3phase transformer
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COOLING OF TRANSFORMERS OF LARGE MVA:
As size of transformer becomes large, the rate of the oil circulating becomes insufficient
to dissipate all the heat produced & artificial means of increasing the circulation by
electric pumps. In very large transformers, special coolers with water circulation may
have to be employed.
TYPES OF COOLING:
Air cooling
1. Air Natural (AN)
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ix. Earth Point
x. Explosion Vent
xi. Temperature Gauge.
xii. Buchholz Relay
xiii. Secondary Terminal
xiv. Primary Terminal
RATING 125MVA
TYPE OF COOLING OFB
TEMP OF OIL 45^C
TEMP WINDING 60^C
KV (no load) HV-233 KVA
LV-10.5 KVA
LINE AMPERES HV-310 A
LV-6880
PHASE THREE
FREQUENCY 50 HZ
IMPEDANCE VOLTAGE 15%
VECTOR GROUP Y DELTA
INSULATION LEVEL HV-900 KV
LV-Neutral-38
CORE AND WINDING WEIGHT 110500 Kg
WEIGHT OF OIL 37200 Kg
TOTAL WEIGHT 188500 Kg
OIL QUANTITY 43900 lit
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GENERATOR TRANSFORMER (166 MVA UNIT-IV)
RATING 240MVA
TYPE OF COOLING ON/OB/OFB
TEMP OF OIL
TEMP WINDING
VOLTS AT NO LOAD HV-236000
LV-A5750
LINE AMPERES HV-587 A
LV-8798
PHASE THREE
FREQUENCY 50 HZ
IMPEDANCE VOLTAGE 15.55%
VECTOR GROUP Y DELTA
CORE AND WINDING WEIGHT 138800 Kg
WEIGHT OF OIL 37850 Kg
TOTAL WEIGHT 234000 Kg
OIL QUANTITY 42500 lit
GUARANTEED MAX TEMP
DIVISION KERELA
YEAR 1977
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UNIT AUXILIARY TRANSFORMER (UAT)
The UAT draws its input from the main bus-ducts. The total KVA capacity of UAT
required can be determined by assuming 0.85 power factor & 90% efficiency for total
auxiliary motor load. It is safe & desirable to provide about 20% excess capacity then
circulated to provide for miscellaneous auxiliaries & possible increase in auxiliary.
STATION TRANSFORMER
It is required to feed power to the auxiliaries during startups. This transformer is normally
rated for initial auxiliary load requirements of the unit in typical cases; this load is of the
order of 60% of the load at full generating capacity. It is provided with on load tap
change to cater to the fluctuating voltage of the grid.
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SWITCH YARD
As we know that electrical energy cant be stored like cells, so what we generate should
be consumed instantaneously. But as the load is not constants therefore we generate electricity according
to need i.e. the generation depends upon load. The yard is the places from where the electricity is send
outside. It has both outdoor and indoor equipments.
OUTDOOR EQUIPMENTS
i. BUS BAR.
ii. LIGHTENING ARRESTER
iii. WAVE TRAP
iv. BREAKER
v. CAPACITATIVE VOLTAGE TRANSFORMER
vi. EARTHING ROD
vii. CURRENT TRANSFORMER.
viii. POTENTIAL TRANSFORMER
ix. LIGHTENING MASK
INDOOR EQUIPMENTS
i. RELAYS.
ii. CONTROL PANELS
iii. CIRCUIT BREAKERS
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BUS BAR
Bus bars generally are of high conductive aluminum conforming to IS-5082 or
copper of adequate cross section .Bus bar located in air insulated enclosures & segregated
from all other components .Bus bar is preferably cover with polyurethane.
BY PASS BUS
This bus is a backup bus which comes handy when any of the buses become faulty. When any
operation bus has fault, this bus is brought into circuit and then faulty line is removed there by
restoring healthy power line.
LIGHTENING ARRESTOR
It saves the transformer and reactor from over voltage and over currents. It
grounds the overload if there is fault on the line and it prevents the generator transformer. The
practice is to install lightening arrestor at the incoming terminal of the line. We have to use the
lightning arrester both in primary and secondary of transformer and in reactors. A meter is
provided which indicates the surface leakage and internal grading current of arrester.
WAVE TRAP
Power line carrier communication (PLCC) is mainly used for telecommunication,
tele-protection and tele-monitoring between electrical substations through power
lines at high voltages, such as 110 kV, 220 kV, and 400 kV. PLCC integrates the
transmission of communication signal and 50/60 Hz power signal through the
same electric power cable. The major benefit is the union of two important
applications in a single system. WAVETRAP is connected in series with
the power (transmission) line. It blocks the high frequency carrier waves (24 KHz
to 500 KHz) and let power waves (50 Hz - 60 Hz) to pass-through.
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BREAKER
Circuit breaker is an arrangement by which we can break the circuit or flow of current. A circuit
breaker in station serves the same purpose as switch but it has many added and complex
features. The basic construction of any circuit breaker requires the separation of
contact in an insulating fluid that servers two functions:
i. extinguishes the arc drawn between the contacts when circuit breaker opens.
ii. It provides adequate insulation between the contacts and from each contact to earth.
EARTHING ROD
Normally un-galvanized mild steel flats are used for earthling. Separate earthing electrodes are
provided to earth the lightening arrestor whereas the other equipments are earthed
by connecting their earth leads to the rid/ser of the ground mar.
CURRENT TRANSFORMER
It is essentially a step up transformer which step down the current to a known
ratio. It is a type of instrument transformer designed to provide a current in
its secondary winding proportional to the alternating current flowing in its
primary.
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POTENTIAL TRANSFORMER
It is essentially a step down transformer and it step downs the voltage to a known ratio.
RELAYS
Relay is a sensing device that makes your circuit ON or OFF. They detect the
abnormal conditions in the electrical circuits by continuously measuring the electrical quantities,
which are different under normal and faulty conditions, like current, voltage frequency. Having
detected the fault the relay operates to complete the trip circuit, which results in the opening of
the circuit breakers and disconnect the faulty circuit.
There are different types of relays:
i. Current relay
ii. Potential relay
iii. Electromagnetic relay
iv. Numerical relay etc.
ELECTROSTATIC PRECIPITATOR
An electrostatic precipitator ( ESP) or electrostatic air cleaner
is a particulate collection device that removes particles from a flowing gas (such
as air) using the force of an induced electrostatic charge. Electrostatic
precipitators are highly efficient filtration devices that minimally impede the flow
of gases through the device, and can easily remove fine particulate matter such as
dust and smoke from the air stream.
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In contrast to wet scrubbers which apply energy directly to the flowing fluid
medium, an ESP applies energy only to the particulate matter being collected and
therefore is very efficient in its consumption of energy (in the form of
electricity).The most basic precipitator contains a row of thin vertical wires, and
followed by a stack of large flat metal plates oriented vertically, with the plates
typically spaced about 1 cm to18 cm apart, depending on the application. The air
or gas stream flows horizontally through the spaces between the wires, and then
passes through the stack of plates. A negative voltage of several thousand volts is
applied between wire and plate. If the applied voltage is high enough an electric
(corona) discharge ionizes the gas around the electrodes. Negative ions flow to
the plates and charge the gas-flow particles.
The ionized particles, following the negative electric field created by the power
supply, move to the grounded plates. Particles build up on the collection plates
and form a layer. The layer does not collapse, thanks to electrostatic pressure
(given from layer resistivity, electric field, and current flowing in the collected
layer).
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CONTROL & INSTRUMENTATION
INTRODUCTION
C&I LABS
CONTROL & MONITORING MECHENISM
PRESSURE MONITORING
TEMPERATURE MONITORING
FLOW MEASUREMENT
CONTROL VALVES
INTRODUCTION
This division basically calibrates various instruments and takes care of any faults occur in
any of the auxiliaries in the plant.
Instrumentation can be well defined as a technology of using instruments to
measure and control the physical and chemical properties of a material.
C&I LABS
Control and Instrumentation Department has following labs:
Manometry Lab.
Protection and Interlocks Lab.
Automation Lab.
Electronics Lab.
Water Treatment Plant.
Furnaces Safety Supervisory System Lab
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OPERATION AND MAINTAINANCE
Control and Instrumentation Department has following Control Units:
This department is the brain of the plant because from the relays to transmitters followed by the
electronic computation chipsets and recorders and lastly the controlling circuitry, all fall under this.
A View of Control Room at BTPS
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1. MANOMETRY LAB
TRANSMITTERS
It is used for pressure measurements of gases and liquids, its working principle is that the
input pressure is converted into electrostatic capacitance and from there it is conditioned
and amplified. It gives an output of 4-20 ma DC. It can be mounted on a pipe or a wall.
For liquid or steam measurement transmitters is mounted below main process piping and
for gas measurement transmitter is placed above pipe.
MANOMETER
Its a tube which is bent, in U shape. It is filled with a liquid. This device corresponds to a
difference in pressure across the two limbs.
ACCURACY
Higher Accuracy implies Larger Dial Size for accuracy of small and readable pressure
scale increments.
SAFETY
While selecting Pressure Gauge it should consider that Gauge Construction Material
should be chemically compatible with the environment either inside or outside it.
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UTILITY
It should keep it mind that range of the Gauge should be according to our need else
Overpressure Failure may occur resulting in damage of Gauge.
PRICE
Lager the Gauges Dial size larger would be our price. Better Gauges Construction
material also increases the cost. So they must be chosen according to our need.
INTERLOCKING
It is basically interconnecting two or more equipments so that if one equipment fails other
one can perform the tasks. This type of interdependence is also created so
that equipments connected together are started and shut down in the specific sequence to
avoid damage. For protection of equipments tripping are provided for all the equipments.
Tripping can be considered as the series of instructions connected through OR GATE,
which trips the circuit. The main equipments of this lab are relay and circuit breakers.
Some of the instrument uses for protection are:
RELAY
It is a protective device. It can detect wrong condition in electrical circuits by constantly
measuring the electrical quantities flowing under normal and faulty conditions. Some
of the electrical quantities are voltage, current, phase angle and velocity. 2. FUSES it is a
short piece of metal inserted in the circuit, which melts when heavy current flows through
it and thus breaks the circuit.
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b. The conductivity of the silver is unimpaired by the surges of the current that
produces temperatures just near the melting point
c. Silver fusible elements can be raised from normal operating temperature to
vaporization quicker than any other material because of its comparatively low
specific heat.
The same circuit achieves both excitation and tripping. Hence the tripping coil is
provided for emergency tripping if the interconnection fails.
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3. AUTOMATION LAB
This lab deals in automating the existing equipment and feeding routes. Earlier, the old
technology dealt with only (DAS) Data Acquisition System and came to be known
as primary systems. The modern technology or the secondary systems are coupled with
(MIS) Management Information System. But this lab universally applies the pressure
measuring instruments as the controlling force. However, the relays are also provided
but they are used only for protection and interlocks.
4. PYROMETRY LAB
THERMOCOUPLES
This device is based on SEEBACK and PELTIER effect. It comprises of two junctions at
different temperature. Then the emf is induced in the circuit due to the flow of electrons.
This is an important part in the plant.
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5. FURNACE SAFETY AND SUPERVISORY SYSTEM LAB
This lab has the responsibility of starting fire in the furnace to enable the burning of coal.
For first stage coal burners are in the front and rear of the furnace and for the second and
third stage corner firing is employed. Unburnt coal is removed using forced draft or
induced draft fan. The temperature inside the boiler is 1100C and its heights 18 to 40 m.
It is made up of mild steel. An ultra violet sensor is employed in furnace to measure the
intensity of ultra violet rays inside the furnace and according to it a signal in the same
order of same mV is generated which directly indicates the temperature of the furnace.
For firing the furnace a 10 KV spark plug is operated for ten seconds over a spray
of diesel fuel and pre-heater air along each of the feeder-mills. The furnace has six feeder
mills each separated by warm air pipes fed from forced draft fans. In first stage indirect
firing is employed that is feeder mills are not fed directly from coal but are fed from three
feeders but are fed from pulverized coalbunkers. The furnace can operate on the
minimum feed from three feeders but under no circumstances should anyone be left
out under operation, to Prevent creation of pressure different with in the furnace, which
threatens to blast it.
6. ELECTRONICS LAB
This lab undertakes the calibration and testing of various cards. It houses various types of
analytical instruments like oscilloscopes, integrated circuits, cards auto analyzers etc.
Various processes undertaken in this lab are:
1. Transmitter converts mV to mA.
2. Auto analyzer purifies the sample before it is sent to electrodes. It extracts the
magnetic portion.
ANNUNCIATIN CARDS
They are used to keep any parameter like temperature etc. within limits. It gets a signal
if parameter goes beyond limit. It has a switching transistor connected to relay that helps
in alerting the UCB.
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CONTROL & MONITORING MECHANISMS
Mechanical Problem can be related to Turbines that is the max speed permissible for a
turbine is3000 rpm so speed should be monitored and maintained at that level.
Metallurgical Problem can be view as the max Inlet Temperature for Turbine is 1060
C so temperature should be below the limit. Monitoring of all the parameters is necessary
for the safety of both:
1. Employees
2. Machines
1. Speed
2. Temperature
3. Current
4. Voltage
5. Pressure
6. Eccentricity
7. Flow of Gases
8. Vacuum Pressure
9. Valves
10. Level
11. Vibration
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PRESSURE MONITORING
For gauges we use Bourdon tubes. The Bourdon Tube is a non-liquid pressure
measurement device. It is widely used in applications where inexpensive static pressure
measurements are needed. A typical Bourdon tube contains a curved tube that is open
to external pressure input on one end and is coupled mechanically to an indicating needle
on the other end, as shows schematically below.
For Switches pressure switches are used and they can be used for digital means of
monitoring as switch being ON is referred as high and being OFF is as low.
All the monitored data is converted to either Current or Voltage parameter.
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The Plant standard for current and voltage are as under
Voltage : 0 10 Volts range
Current : 4 20 milli-Amperes
We use 4mA as the lower value so as to check for disturbances and wire breaks.
Accuracy of such systems is very high.
ACCURACY: 0.1 %
Programmable Logic Circuits (PLCs) are used in the process as they are the heart
of Instrumentation.
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TEMPERATURE MONITORING
We can use Thermocouples or RTDs for temperature monitoring. Normally RTDs are
used for low temperatures.
1. Temperature Range
2. Accuracy Required
RTDs are also used but not in protection systems due to vibrational errors.
We pass a constant current through the RTD. So that if R changes then the Voltage also
changes
For Analog medium thermocouples are used and for Digital medium Switches are used
which are basically mercury switches.
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FLOW MEASUREMENT
Flow measurement does not signify much and is measured just for metering purposes and
for monitoring the processes
ROTAMETERS:
A Rotameter is a device that measures the flow rate of liquid or gas in a closed tube. It is
occasionally misspelled as 'Rotometer'.
It belongs to a class of meters called variable area meters, which measure flow rate
by allowing the cross sectional area the fluid travels through to vary, causing some
measurable effect. A rotameter consists of a tapered tube, typically made of glass, with a
float inside that is pushed up by flow and pulled down by gravity. At a higher flow rate
more area (between the float and the tube) is needed to accommodate the flow, so the
float rises. Floats are made in many different shapes, with spheres and spherical ellipses
being the most common. The float is shaped so that it rotates axially as the fluid passes.
This allows you to tell if the float is stuck since it will only rotate if it is not.
1. Flow meters
2. Venturimeters / Orifice meters
3. Turbines
4. Mass flow meters (oil level)
5. Ultrasonic Flow meters
6. Magnetic Flow meter (water level )
Selection of flow meter depends upon the purpose, accuracy and liquid to be measured so
different types of meters used.
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TURBINE TYPE:
They are simplest of all. They work on the principle that on each rotation of the turbine a
pulse is generated and that pulse is counted to get the flow rate.
VENTURIMETERS :
Referring to the diagram, using Bernoulli's equation in the special case of incompressible
fluids (such as the approximation of a water jet), and the theoretical pressure drop at the
constriction would be given by (/2)(v22- v12).
And we know that rate of flow is given by:
Flow = k (D.P)
Where DP is Differential Pressure or the Pressure Drop.
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CONTROL VALVES
A valve is a device that regulates the flow of substances (either gases, fluidized solids,
slurries, or liquids) by opening, closing, or partially obstructing various passageways.
Valves are technically pipe fittings, but usually are discussed separately. Valves are
used in a variety of applications including industrial, military, commercial, residential,
transportation. Plumbing valves are the most obvious in everyday life, but many more are
used.
Some valves are driven by pressure only, they are mainly used for safety purposes in
steam engines and domestic heating or cooking appliances. Others are used in
a controlled way, like in Otto cycle engines driven by a camshaft, where they play a
major role in engine cycle control.
Many valves are controlled manually with a handle attached to the valve stem. If the
handle is turned a quarter of a full turn (90) between operating positions, the valve
is called a quarter-turn valve. Butterfly valves, ball valves, and plug valves are often
quarter-turn valves. Valves can also be controlled by devices called actuators attached to
the stem. They can be electromechanical actuators such as an electric motor or solenoid,
pneumatic actuators which are controlled by air pressure, or hydraulic actuators which
are controlled by the pressure of a liquid such as oil or water. So there are basically three
types of valves that are used in power industries besides the handle valves.
They are :
PNEUMATIC VALVES They are air or gas controlled which is compressed to turn or
move them
HYDRAULIC VALVES They utilize oil in place of Air as oil has better compression
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FURNACE SAFEGUARD SUPERVISORY SYSTEM
The 95 MW boilers are indirect type boilers. Fire takes place in front and in rear side.
Thats why its called front and rear type boiler.
The 210 MW boilers are direct type boilers (which means that HSD is in direct contact
with coal) firing takes place from the corner. Thus it is also known as corner type boiler.
IGNITER SYSTEM
Igniter system is an automatic system, it takes the charge from 110kv and this spark is
brought in front of the oil guns, which spray aerated HSD on the coal for coal
combustion. There is a 5 minute delay cycle before igniting, this is to evacuate or burn
the HSD. This method is known as PURGING.
PRESSURE SWITCH
Pressure switches are the devices that make or break a circuit. When pressure is applied,
the switch under the switch gets pressed which is attached to a relay that makes or break
the circuit.
Time delay can also be included in sensing the pressure with the help of pressure valves.
Examples of pressure valves:
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REFERNCES
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APPENDIX
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