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Full Summer Training Report On Power Plant
Full Summer Training Report On Power Plant
UNDERTAKEN AT
Haridwar
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Bharat Heavy Electricals Ltd. (BHEL) Haridwar has two manufacturing plants and one captive
power plant. I was assigned to do my training in the captive power plant.
Capacity-23.6 MW.
It is coal fired.
Operation
This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold
mixture P.A fan. This fan takes atmospheric air, a part of which is sent to pre heaters while a
part goes to the mill for temperature control. Atmospheric air from F.D fan in the air heaters
and sent to the furnace as combustion air.
Water from boiler feed pump passes through economizer and reaches the boiler drum . Water
from the drum passes through the down comers and goes to the bottom ring header. Water
from the bottom ring header is divided to all the four sides of the furnace. Due to heat density
difference the water rises up in the water wall tubes. This steam and water mixture is again
taken to the boiler drum where the steam is sent to super heaters for super heating. The super
heaters are located inside the furnace and the steam is super heated (540 degree Celsius) and
finally it goes to the turbine.
Fuel gases from the furnace are extracted from the induced draft fan, which maintains balance
draft in the furnace with F.D fan. These fuel gases heat energy to the various super heaters and
finally through air pre heaters and goes to electrostatic precipitators where the ash particles
are extracted. This ash is mixed with the water to from slurry is pumped to ash period.
The steam from boiler is conveyed to turbine through the steam pipes and through stop valve
and control valve that automatically regulate the supply of steam to the turbine. Stop valves
and controls valves are located in steam chest and governor driven from main turbine shaft
operates the control valves the amount used.
Steam from controlled valves enter high pressure cylinder of turbines, where it passes through
the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a
second ring of moving blades mounted on the disc secured in the turbine shaft. The second
ring turns the shaft as a result of force of steam. The stationary and moving blades together.
Cooling water pump Three-phase transmission line Step up transformer Electrical Generator
Low pressure steam Boiler feed water pump Surface condenser Intermediate pressure steam
turbine Steam control valve High pressure steam turbine Deaerator Feed water heater Coal
conveyor Coal hopper Coal pulverizer Boiler steam drum Bottom ash hoper Super heater
Forced draught fan
Reheater Combustion air intake Economizer Air preheater Precipitator Induced draught(draft)
fan Fuel gas stack
Cooling towers
Cooling Towers are evaporative coolers used for cooling water or other working medium to
near the ambivalent web-bulb air temperature. Cooling tower use evaporation of water to
reject heat from processes such as cooling the circulating water used in oil refineries, Chemical
plants, power plants and building cooling, for example. The tower 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 structure 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
primary use of large , industrial cooling tower system is to remove the heat absorbed in the
circulating cooling water systems used in power plants , petroleum refineries, petrochemical
and chemical plants, natural gas processing plants and other industrial facilities . The absorbed
heat is rejected to the atmosphere by the evaporation of some of the cooling water in
mechanical forced-draft or induced draft towers or in natural draft hyperbolic shaped cooling
towers as seen at most nuclear power plants.
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 may be a
reciprocating or turbine steam engine, , water falling through the turbine are made in a variety
of sizes ranging from small 1 hp (0.75 kW) units (rare) used as mechanical drives for pumps,
compressors and other shaft driven equipment , to 2,000,000 hp(1,500,000 kW) turbines used
to generate electricity. There are several classifications for modern steam turbines.
Steam turbines are used in all of our 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
station use large stem 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.
Energy in the steam after it leaves the boiler is converted into rotational energy as it passes
through the turbine. The turbine normally consists of several stage with each stages consisting
of a stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential
energy of the steam into kinetic energy into 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.
Steam-powered pumps
Steam locomotives and the steam engines used on ships and stationary applications such as
power plants also required feed water pumps. In this situation, though, the pump was often
powered using a small steam engine that ran using the steam produced by the boiler. A means
had to be provided, of course, to put the initial charge of water into the boiler(before steam
power was available to operate the steam-powered feed water pump).the pump was often a
positive displacement pump that had steam valves and cylinders at one end and feed water
cylinders at the other end; no crankshaft was required.
In thermal plants, the primary purpose of surface condenser is to condense the exhaust steam
from a steam turbine to obtain maximum efficiency and also to convert the turbine exhaust
steam into pure water so that it may be reused in the steam generator or boiler as boiler feed
water. By condensing the exhaust steam of a turbine at a pressure below atmospheric
pressure, the steam pressure drop between the inlet and exhaust of the turbine is increased,
which increases the amount heat available for conversion to mechanical power. Most of the
heat liberated due to condensation of the exhaust steam is carried away by the cooling
medium (water or air) used by the surface condenser.
Control valves
Control valves are valves used within industrial plants and elsewhere to control operating
conditions such as temperature,pressure,flow,and liquid Level by fully partially opening or
closing in response to signals received from controllers that compares a set point to a
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
Deaerator
A Dearator 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 noncorrosive. 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 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)
MAIN GENERATOR
Maximum continuous KVA rating Maximum continuous KW Rated terminal voltage Rated
Stator current Rated Power Factor Excitation current at MCR Condition Slip-ring Voltage at
MCR Condition Rated Speed Rated Frequency Short circuit ratio Efficiency at MCR Condition
Direction of rotation viewed Phase Connection Number of terminals brought out
24700KVA 210000KW 15750V 9050 A 0.85 lag 2600 A 310 V 3000 rpm 50 Hz 0.49 98.4% Anti
Clockwise Double Star 9( 6 neutral and 3 phase)
CONTROL AND INSTRUMENTATION
Temperature
The hotness or coldness of a piece of plastic, wood, metal, or other material depends upon the
molecular activity of the material. Kinetic energy is a measure of the activity of the atoms
which make up the molecules of any material. Therefore, temperature is a measure of the
kinetic energy of the material in question. 1. RTD The resistance of an RTD varies directly
with temperature: - As temperature increases, resistance increases. - As temperature
decreases, resistance decreases. RTDs are constructed using a fine, pure, metallic, spring-
like wire surrounded by an insulator and enclosed in a metal sheath. A change in
temperature will cause an RTD to heat or cool, producing aproportional change in resistance.
The change in resistance is measured by a precision device that is calibrated to give the proper
temperature reading.
Flow meters
Differential Flow Transmitter Orifice plates
Flat plates 1/16 to 1/4 in. thick Mounted between a pair of flanges Installed in a
straight run of smooth pipe to avoid disturbance of flow patterns due to fittings and valves
Venturi tube
Converging conical inlet, a cylindrical throat, and a diverging recovery cone No
projections into the fluid, no sharp corners, and no sudden changes in contour
Only single sensor i.e. level sensor is used to control the level
This uses two sensors level and flow sensors. It is better and precise than single element
control.
Ratio Control
Ratio control is used to ensure that two flows are kept at the same ratio even if the flows are
changing. E.g. Air-Fuel Ratio where the proper ratio between air and fuel i.e. pulverized coal
has to be maintained.
Controller feed is adjusted according to the ratio of wild feed. The implementation is shown
above.
Automation of Processes
The main purpose of automation is to minimize human intervention to reduce the errors.
Large processes like power plant has large scope for errors. The automation of industrial
processes is carried by PLCs and SCADA.
The above figure shows the hierarchy setup of industrial automation. The field devices are
connected to the PLC and all the PLCs are connected to the SCADA server based in control
room. The SCADA server is connected via LAN to ERP (Enterprise Resource Planning) and the
data can be accessed from any where on internet.
PLC (Programmable Logic Controller)
Digital electronic device that uses a programmable memory to store instructions and to
implement specific functions such as logic , sequencing , timing etc to control machine and
processes. Salient features Cost effective for controlling complex systems. Flexible and
can be reapplied to control other systems quickly and easily. Computational abilities allow
more sophisticated control. Trouble shooting aids make programming easier and reduce
downtime. Reliable components make these likely to operate for years before failure. PLC
HARDWARE Many PLC configurations are available, even from a single vendor. But, in each of
these there are common components and concepts. The most essential components are:
Power Supply - This can be built into the PLC or be an external unit. Common voltage levels
required by the PLC (with and without the power supply) are 24Vdc, 120Vac, 220Vac. CPU
(Central Processing Unit) - This is a computer where ladder logic is stored and processed. I/O
(Input/Output) - A number of input/output terminals must be provided so that the PLC can
monitor the process and initiate actions. Indicator lights - These indicate the status of the PLC
including power on, program running, and a fault. These are essential when diagnosing
problems. The configuration of the PLC refers to the packaging of the components. Rack - A
rack is often large (up to 18 by 30 by 10) and can hold multiple cards. When
necessary, multiple racks can be connected together. These tend to be the highest cost, but
also the most flexible and easy to maintain. INPUTS AND OUTPUTS
Inputs to, and outputs from, a PLC are necessary to monitor and control a process. Both inputs
and outputs can be categorized into two basic types: logical or continuous. Consider the
example of a light bulb. If it can only be turned on or off, it is logical control. If the light can be
dimmed to different levels, it is continuous. Continuous values seem more intuitive, but logical
values are preferred because they allow more certainty, and simplify control. As a result most
controls applications (and PLCs) use logical inputs and outputs for most applications. Hence,
we will discuss logical I/O and leave continuous I/O for later. Outputs to actuators allow a PLC
to cause something to happen in a process. A short list of popular actuators is given below in
order of relative popularity. Solenoid Valves - logical outputs that can switch a hydraulic or
pneumatic flow. Lights - logical outputs that can often be powered directly from PLC
output boards. Motor Starters - motors often draw a large amount of current when
started, so they require motor starters, which are basically large relays. Servo Motors - a
continuous output from the PLC can command a variable speed or position. Outputs from PLCs
are often relays, but they can also be solid state electronics such as transistors for DC outputs
or Triacs for AC outputs. Continuous outputs require special output cards with digital to analog
converters. Inputs come from sensors that translate physical phenomena into electrical signals.
Typical examples of sensors are listed below in relative order of popularity. Proximity
Switches - use inductance, capacitance or light to detect an object logically. Switches -
mechanical mechanisms will open or close electrical contacts for a logical signal.
Potentiometer - measures angular positions continuously, using resistance. LVDT (linear
variable differential transformer) - measures linear displacement
Step 1-CHECK INPUT STATUS-First the PLC takes a look at each input to determine if it is on or
off. In other words, is the sensor connected to the first input on? How about the second input?
How about the third... It records this data into its memory to be used during the next step.
Step 2-EXECUTE PROGRAM-Next the PLC executes your program one instruction at a time.
Maybe your program said that if the first input was on then it should turn on the first output.
Since it already knows which inputs are on/off from the previous step it will be able to decide
whether the first output should be turned on based on the state of the first input. It will store
the execution results for use later during the next step. Step 3-UPDATE OUTPUT STATUS-Finally
the PLC updates the status of the outputs. It updates the outputs based on which inputs were
on during the first step and the results of executing your program during the second step.
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true.
Drawing the ladder logic for flowchart The flowchart is the most encountered problems in
industrial processes