TRAINING REPORT

AN OVERVIEW OF THE GAS POWER PLANT

SUBMITTED BY:

JYOTI TOMER
Roll No.- 1140900
ELECTRICAL ENGINEERING,4TH year
NATIONAL INSTITUTE of TECHNOLOGY
KURUKSHETRA

JUNE -JULY 2017

 CONTENTS

 ACKNOWLEDGEMENT
 ABOUT THE COMPANY
 INTRODUCTION TO FARIDABAD GAS POWER
PLANT
 CONVERSION FROM GAS TO ELECTRICITY
 OPERATIONS AND FUEL HANDLING
DEPARTMENT
 ELECTRICAL MANAGEMENT
 MAINTENANCE AND PLANNING DIVISION
 INFORMATION AND TECHNOLOGY
DEPARTMENT
 CHEMISTRY DEPARTMENT
 A STUDY OF CONTROL AND INSTRUMENTATION
DEPARTMENT
 CONCLUSION
 ACKNOWLEDGMENT

I would like to thank the management of NTPC for their support

during my training in the organisation. I would also like to thank
the employees at NTPC- Mr. Rajiv Pandey, Mr. Vivek Bafana, Mr.
Amit Tyagi, Mr. Deepesh Jain, Mr. Rajeev Ahlawat, Mr. Kulbir
Singh and all the technicians in various departments for their
invaluable guidance and the knowledge they have imparted me
with. They also helped me understand the technicalities
minutely. Without their assistance, this project could not have
been completed successfully.
 ABOUT THE COMPANY

Corporate Vision:
“A world class integrated power major, powering India’s growth,
with increasing global presence”

Core Values:
B-Business Ethics
C-Customer Focus
O-Organizational & Professional pride
M-Mutual Respect and Trust
I- Innovation & Speed
T-Total quality for Excellence
E - Enterprising
D - Devoted

NTPC Limited is the largest thermal power generating company

of India. A public sector company, it was incorporated in the
year 1975 to accelerate power development in the country as a
wholly owned company of the Government of India. At present,
Government of India holds 89.5% of the total equity shares of
the company and the balance 10.5% is held by FIIs, Domestic
Banks, Public and others. Within a span of 31 years, NTPC has
emerged as a truly national power company, with power
generating facilities in all the major regions of the country.
 EVOLUTION OF NTPC

NTPC was set up in 1975 with 100%

1975
ownership by the Government of India. In the
last 30 years, NTPC has grown into the largest
power utility in India.

In 1997, Government of India granted NTPC

1997 status of “Navratna’ being one of the nine
jewels of India, enhancing the powers to the
Board of Directors.

NTPC became a listed company with majority

2004 Government ownership of 89.5%.
NTPC becomes third largest by Market
Capitalisation of listed companies

2005 The company rechristened as NTPC Limited

in line with its changing business portfolio and
transform itself from a thermal power utility to
an integrated power utility.

NTPC is the largest power utility in India, accounting for

about 20% of India’s installed capacity.
INTRODUCTION TO FARIDABAD GAS POWER PLANT

NTPC-Faridabad was approved on 25th July 1997. The total

project cost was 1163 cr. INR. The plant was fully functional in
the year 2000 with an installed capacity of 432 MW. The plant
under an agreement with the Haryana government supplies the
entire power generated to the state of Haryana only.
Faridabad gas power plant is a combined cycle power plant
having a net capacity of 432MW. It consists of two gas turbines
with capacity of 138MW each and a steam turbine with the
capacity of 156MW. The main fuel used here is natural gas. In
case of the unavailability or shortage of natural gas the
alternative fuel used is naphtha. Since the production cost with
naphtha differs from that with natural gas by Rs. 6-7 per unit,
naphtha is not used as a main fuel.
The power plant is called the combined cycle power plant
because the heat energy liberated during the combustion of
natural gas is not dissipated into the environment but is utilised
for the generation of steam which rotates the steam turbine.

Salient Features of this project are:

1. Project Faridabad Gas Power Project

2. Location
3. Plant Capacity
4. Plant Configuration
5. Mode of Operation
6. Fuel
7. Alternate Fuel
8. Average Gas requirement
Village Mujedi, P.O. Neemka,
Faridabad, Haryana
432 MW
Gas Turbine 1 - 138 MW
Gas Turbine 2 - 138 MW
Steam Turbine - 156 MW
Base Load
Natural Gas
Naphtha / HSD
2 million cubic meters per day
9. Fuel Source HBJ pipe line (through GAIL)
10. Cooling water Rampur Distributory source
11. Naphtha Storage 2 tanks of 8000 Kl. Capacity
each.
12. HSD Storage 1 tank of capacity 400 Kl.
13. Power Evacuation 2X220 KV Double circuit lines
each to 220KV BBMB sub-
station at Samaypur
(Ballabgarh) and HVPN sub-
station at Palla (Faridabad)

NTPC-Faridabad is a power (electricity) generating company

with installed plant capacity of 432 MW. The plant configuration
is as under:
Gas Turbine -1 138 MW
Gas Turbine -2 138 MW
Steam Turbine 156 MW

The mode of operation is “Base Load”. Natural Gas is used as

main fuel. Naphtha is used as an alternate fuel. Average gas
requirement is two million cubic meters per day. Gas Authority
of India Ltd. supplies Natural Gas to the plant through their
H.B.J. Gas pipeline. The electricity generated is supplied to the
state of Haryana.

The High Speed Diesel (HSD) which is used during a gas

shortage is supplied to NTPC-Faridabad by Indian Oil Co.
(IOCL).
Water, which is an important pre-requisite for any thermal
power plant, is obtained through the Agra canal which runs
through the Faridabad city.
The Gas turbines used at NTPC–Faridabad is obtained from
SIEMENS which is the OEM (Original Equipment
Manufacturer). The model used in this plant is V 94.2(model-3).
 CONVERSION FROM GAS TO ELECTRICITY

The basic principle of the Combined Cycle is simple: burning

gas in a gas turbine (GT) produces not only power - which can
be converted to electric power by a coupled generator but also
extremely hot exhaust gases. Routing these gases through a
water-cooled heat exchanger produces steam, which can be
turned into electric power with a coupled steam turbine and
generator.

This set-up of Gas Turbine, waste-heat boiler, steam turbine

and generators is called a combined cycle. This type of power
plant is being installed in increasing numbers round the world
where there is access to substantial quantities of natural gas.
This type of power plant produces high power outputs at high
efficiencies and with low emissions. It is also possible to use
the steam from the boiler for heating purposes so such power
plants can operate to deliver electricity alone.

The electricity produced here is supplied to the distribution

grids as well as used to operate the plant. In case of total
power failure, the plant is operated using a Black Star Diesel
Generator set. The exciter of the turbine as well as other
machinery is coupled to both the BSDG as well as main power
supply. In case of power failure, the power source is
automatically switched to BSDG supply.
Efficiencies are very wide ranging depending on the lay-out and
size of the installation. Developments needed for this type of
energy conversion is only for the gas turbine. Both waste heat
boilers and steam turbines are in common use and well-
developed, without specific needs for further improvement.
 AIR INTAKE SYSTEM

AIR FILTERS

(AN ARRAY OF 576 FILTERS) Flue gas discharged in the atmosphere

after treatment (temp. 500C)

AIR COMPRESSOR
LP steam outlet
(16 STAGE COMPRESSOR)

LOW
PRESSURE
COMBUSTION CHAMBERS
BOILER
NATURAL GAS DRUM
2 combustion chambers,
each having 8 burners
LP steam

Water inlet HIGH

PRESSURE
GAS TURBINE
BOILER
(A 4 stage turbine) DRUM

FLUE GAS (Temp. HP steam

GENERATOR 5400C) HIGH LOW
PRESSURE PRESSURE
10.5KV Generated on TURBINE TURBINE
rotation of gas turbine

STEP-UP TRANSFORMER STEP-UP TRANSFORMER GENERATOR

15.75KV generated on CONDENSER

10.5KV to 220KV step-up 15.75KV to 220KV step-up
rotation of steam turbine

Hot well

DEAERATOR
TRANSMISSION GRID
CONDENSATE
EXTRACTION PUMPS
For distribution FEED STORAGE

UNIT AUXILLIARY TRANSFORMER

HP Boiler feed pumps LP Boiler feed pumps
Step down to 6.6 KV

To power plant machinery

HP Boiler drum LP Boiler drum
The above diagram depicts the process of conversion of natural
gas to electricity. It is a combined cycle which utilises the heat
of the flue gas to heat the water and operate the steam turbine.
The step by step description of the process and the machinery
is as follows:

1. Air Intake System:

The air intake system consists of huge suction pumps in order

to meet the air requirements. The air to fuel ratio is 11:1. Thus
the amount of air being taken in is controlled so as to keep this
ratio constant.

The view of air intake system at NTPC Faridabad

 2. Air filters

The air obtained from the environment contains numerous

pollutants and unwanted compounds which may harm the
machinery and reduce the efficiency of the system. These
unwanted compounds may also react with the surface of the
machinery and cause scaling which would subsequently reduce
the lifetime of the machinery. To overcome this problem, the air
is passed through the filter section. This section consists of an
array of 576 filters to eliminate all the unwanted particles and
compounds present in the air.

3. Air compressor

The filtered air is then passed through the compressor section.

The compression of air takes place in 16 stages. The
compression reduces the temperature of air. To compensate
the heat loss and prevent the temperature shock in the next
stage, heat addition is done in the next stage of combustion.

A sectional view of an air compressor

 4. Combustion chamber

After compression, the air is sent to the combustion chamber

where 11 parts of air is burnt with one part of natural gas. This
leads to the expansion of air which is used to rotate the turbine.
Each turbine section is preceded by two combustors. Each
combustor consists of eight burners.

The above picture shows a cross- sectional view of

a combustor used in the combustion chamber.
Fuel enters the front of the burner as an atomized spray or in a
pre-vaporized form. Air flows in around the fuel nozzle and
through the first row of combustion air holes in the liner. Air
near the burner nozzle stays close to the front liner wall for
cooling and cleaning purposes. Air entering the opposing liner
holes mixes rapidly with the fuel to form a combustible mixture.
Air entering the forward section of the liner recirculates and
moves upstream against the fuel spray. During combustion, this
action permits rapid mixing and prevents flame blowout by
forming a low-velocity stabilization zone. This zone acts as a
continuous pilot for the rest of the burner. Air entering the down
stream part of the liner provides the correct mixture for
combustion. This air also creates the intense turbulence
necessary for mixing the fuel and air and for transferring energy
from the burned to the unburnt gases. Since an engine usually
has two ignition plugs, cross ignition tubes are necessary in the
can and can-annular types of burners. These tubes allow
burning to start in the other cans or inner liners.

5. Gas turbine

PRINCIPLE OF GAS TUBINE:

1. Works on Baryon Cycle

2. It is an open cycle process
3. Isentropic compression and expansion takes place.
4. Constant pressure heat addition takes place.

The air from the combustion chamber creates thrust on the

turbine blades to provide rotation.
The Gas Turbine used at NTPC-Faridabad is V94.2 (model-3)
is manufactured by SIEMENS

The Gas Turbine used at NTPC-Faridabad is V94.2 (model-3) manufactured by

SIEMENS

DETAILS OF THE GAS TURBINE GENERATOR

Apparent power 170.12MVA

Active Power 144.6MW
Current 9354A
Voltage 10.5KV+/-5%

Speed 3000rpm

Frequency 50Hz

Power Factor 0.85

Stator Winding YY

Rated Field current 833A

Rated Field Voltage 410V

Efficiency 50%
 6. Generator

The rotation of gas turbine leads to the rotation of the rotor part
of the generator which is connected to the same shaft as that of
the turbine.

Generator

Turbine and the generator mounted on a single shaft

7. Step up transformer

The electricity is generated at 10.5KV. But this voltage is very

less for the purpose of transmission over a long distance and
hence the step-up transformer is used to step up the voltage
from 10.5KV to 220KV.
 A step up transformer

8. Unit auxiliary transformer

For the purpose of running the machinery of the plant and

exciting the generator, the power obtained from the gas
turbine is utilised. Since the machinery is operated at
6.6KV, the voltage is first stepped down from 10.5KV to
6.6KV using the unit auxiliary transformer and then
supplied within the plant.

An auxiliary transformer
 9. High pressure boiler drum

The flue gas from the turbine has a very high temperature of
0
540 C. This is utilised to heat the water in the boiler drums.
High power boiler drum absorbs most of the heat from the flue
gas and thus generates high power steam.

10. Low pressure boiler drum

The remaining heat is absorbed by the low power boiler drum.

Thus low power steam is generated.
Both the low power and high power steams are sent to the
steam turbine.

11. Steam turbine

It is divided into two sections, High pressure and low pressure

turbine. The high pressure turbine receives HP steam i.e. 85
2
Kg/cm , while the low pressure turbine receives the low
2
pressure steam i.e. 4-5 Kg/ cm .

A steam turbine
DETAILS OF THE STEAM TURBINE GENERATOR

Apparent power 188.23MVA

Active Power 160MW
Current 6900A
Voltage 15.75KV+/-5%
Speed 3000rpm
Frequency 50Hz
Power Factor 0.85
Stator Winding YY
Rated Field current 798A
Rated Field Voltage 432V

Efficiency 45%

12. Condenser
The condenser condenses the steam from the exhaust of the
turbine into liquid to allow it to be pumped. If the condenser can
be made cooler, the pressure of the exhaust steam is reduced
and efficiency of the cycle increases.

The surface condenser is a shell and tube heat exchanger in

which cooling water is circulated through the tubes. The
exhaust steam from the low pressure turbine enters the shell
where it is cooled and converted to condensate (water) by
flowing over the tubes.
For best efficiency, the temperature in the condenser must be
kept as low as practical in order to achieve the lowest possible
pressure in the condensing steam. Since the condenser
temperature can be kept below 100 °C, where the vapour
pressure of water is much less than atmospheric pressure, the
condenser generally works under vacuum. Thus two vacuum
pumps are used to maintain the vacuum pressure of 0.9
2
Kg/cm . A third vacuum pump is kept on stand by in case of
emergency.

The water thus condensed is sent to the de-aerator for the

removal of air. This is done by the condensate extraction
pumps.

13. Steam turbine generator

As the thrust is created on the steam turbine blades, the rotor

section of the generator to which the turbine is connected, is
rotated due to the rotation of the turbine shaft. This generates
power of 156 MW and a voltage of 15.75 KV is generated
which is then stepped up at the next stage and sent for
transmission.

Constructional view of Heat Recovery Steam Generator

 A view of the steam turbine generator

14. Step up transformer

The voltage generated from the steam turbine is 15.75 KV

which is very less for the purpose of transmission over a long
distance. The voltage is thus stepped up using a voltage step
up transformer.

A typical step up transformer

 15. De-aerator

The water from the condenser is led here by the condensate

extraction pumps. The de-aerating boiler feedwater system
eliminates the need of expensive oxygen scavenger chemicals
and also offers the following advantages:

 Removes carbon dioxide as well as oxygen.

 Raises the boiler feedwater temperature, eliminating
thermal shock in boilers.
 Improves overall boiler room efficiency.
 Feedwater pumps are sized for each individual application
- assuring total compatibility and optimum operation.

PRINCIPLE: Paging scheme-high temperature breaks down

the gases and expels the air.

HOW DOES IT WORK?

Aerated water is fed into the de-aerator through the inlet water
connection. This water passes through the steam-filled heating
and venting section. The water temperature is raised and many
of the undissolved gases are released. As the water passes
through the assembly, it flows to a scrubber section where final
de-aeration is accomplished by scrubbing the water with
oxygen free steam. This steam is induced through a stainless
steel spray valve assembly which causes the high velocity
steam to break the water down to a fine mist through a violent
scrubbing action. The de-aerated water spills over to the tanks
storage compartment for use by the boiler, and the gases are
vented to the atmosphere.
 De-aerator

16. Feed storage

The de-aerated water is then stored into the feed storage tank
and is pumped out when required.

17. Boiler feed pumps

They are used to pump the water from the feed storage tank to
the respective boiler drums. They are classified as high and low
pressure boiler feed pumps based on the boiler drum to which
they pump the water.

18. Cooling towers

A cooling tower is equipment used to reduce the temperature of

a water stream by extracting heat from water and emitting it to
the atmosphere. Cooling towers make use of evaporation
whereby some of the water is evaporated into a moving air
stream and subsequently discharged into the atmosphere.
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. Materials are chosen to
enhance corrosion resistance, reduce maintenance, and
promote reliability and long service life. Galvanized steel,
various grades of stainless steel, glass fibre, and concrete are
widely used in tower construction

PLANT EFFECIENCY

When the plant is running in open cycle i.e. when the gas
turbine is only running then the efficiency is a mere 30% but if
we run the plant in a closed combined cycle which includes the
gas as well as the steam turbines then we can achieve an
efficiency of about 50%. Thus it is profitable to run the plant in a
combined cycle mode.

The flow diagram of a combined cycle power plant is given

below:
The above diagram thus shows the efficiency of a thermal
power plant and the power losses at various stages.

Thus on accounting various power losses, the net efficiency of

the power plant comes out to lie between 45%-50%.
For the proper functioning and maintenance of the plant, the
various departments of NTPC along with their basic functioning
are as follows:

OPERATIONS AND FUEL HANDLING

This department handles the operations of the plant by

managing the fuel and all the machinery related to the
monitoring and controlling the various parameters of the fuel.
The natural gas is supplied to the plant through the HBJ
pipeline based on the requirement. It is then used as per
requirement.

For emergency purposes, the plant stores 16000Kl of naphtha

at any point of time.
During the generation of electricity using naphtha, the naphtha
is dosed with HSD (High Sulphur Diesel) to form a favourable and
efficient combustible fuel.

Storage of naphtha: Naphtha is piped through the Asavati

pipeline as per the order placed and is pumped into the
reservoirs using two unloading pumps. Its flow into the
reservoirs is then monitored using the proper measuring
instruments.
Naphtha is stored in two 8000Kl reservoirs made of cement
and RCC walls. The reservoirs are inverted bowl floating roof
type to prevent any air inside the chamber which may cause a
2
harmful reaction with naphtha. A pressure of 28Kg/cm is
maintained inside the reservoirs. Also, the chamber is insulated
completely in order to control the temperature and prevent
combustion of naphtha owing to high temperature.
 Naphtha storage tanks

Storage of HSD: HSD is supplied by the Indian oil co. via

tankers. It is then stored in the reservoirs and used as per the
needs. The reservoirs are fixed roof type.

Fire fighting structure: Both the reservoirs are protected by a

foam pump house situated near the reservoirs. In case of fire,
the automatic fire combat systems get enabled and the foam is
pumped at such an angle so that it settles on the roof of the
reservoir and cuts-off the oxygen supply to the fuel.

Forwarding of the fuel: Naphtha is sent to the reservoirs using

the unloading pumps. When required, it is pumped out and sent
to the dosing chamber using three forwarding pumps.
The HSD is also pumped from the reservoirs to the dosing
chamber by two forwarding pumps.
 EEMG (ELECTRICAL MANAGEMENT)

This department manages the supply of electricity to various

grids as per their requirements. It also monitors the timely
requirements at the grid and despatches the power accordingly.

This department works in constant co-ordination with the

Northern Regional Load Despatch Centre (NRLDC). NRLDC
monitors the requirement and power schedule of the northern
region. It governs the power despatch and load shedding based
on the meteorological parameters and the previous requirement
statistics.
It thus sends its requirement schedule for the next day to and
accordingly the power is despatched to the grid for distribution.
It also sends the supply and demand statistics in 15 minute
blocks to match up with the schedule.

 Declared capability (DC): it is the maximum power NTPC

plant could generate which is told to NRLDC. The
schedule must be less than or equal to the declared
capability.

 The unstable frequency leads to less efficiency and

Unscheduled Interchange. At lower frequency the
unscheduled interchange rate is high whereas for high
frequency, it is low.
The bigger grid leads to higher stability. Thus to maintain
the stability the grid size is kept sufficiently large and
breakers are used.
MAINTENANCE & PLANNING DIVISION (MTP)
It is divided into two other divisions namely:

1. Mechanical maintenance
2. Electrical maintenance

This dept. is needed because of the below stated reasons:

1. To take up the daily maintenance of the plant as per

schedule.

2. It is not possible to maintain the plant daily so a schedule

is needed which is drawn up by this dept.

3. It takes up rectifying work in case of a machine or an

electrical failure.

4. It is responsible for the overhauling of the plant.

5. It monitors the condition and the working of the plant to

check if everything is working well.

6. It arranges for spares from the OEM (Original Equipment

Manufacturer) and from other suppliers.

7. This department also oversees the work of the workshop

within the plant whose work is to manufacture small parts.

8. The MTP also undertakes the regular calibration of all the

instruments and the sensors.

9. There is a weekly meeting for contracts and material in

the department.
 I. OPERATIONS (MECHANICAL)

The O&M (mechanical) department at NTPC- Faridabad takes

care of day to day running the mechanical components of the
plants in a safe and in an efficient manner. The main
mechanical components are listed below:
1. Gas Turbine
2. Steam Turbine
3. Pumps
4. Heat Recovery Steam generator (HRSG)

The procedure:
 The maintenance and planning department first given an
isolation request by the mechanical maintenance
department.
 It is then forwarded to the control department for analysis
and isolation permission or denial is given accordingly.
 The machine is then overhauled, refurbished and reused.

Since the isolation and overhauling must be done for proper

functioning of the plant, various time limits have been set up for
different parts of the plant. These must not be exceeded. They
are counted in Equivalent Operating Hours (EOH).

 A minor inspection is done after every 4000 EOH.

 A hot gas path inspection is done after every 3000 EOH.
 A major inspection is conducted after every 66000 EOH in
which the turbines are also overhauled and refurbished.
II. OPERATIONS (ELECTRICAL)

The OPERATONS (ELECTRICAL) department at NTPC

Faridabad takes care of the running of the electrical systems as
well as maintaining them.

The electrical overview of the plant is shown below:

The electrical maintenance department thus looks into the

proper functioning and working of al the electrical equipments.
The various categories of electrical maintenance are:

 Condition based maintenance: it is done in order to

prevent any fault that may creep into the system. Thus
various parameters of the machinery and electrical path
 are recorded periodically and any fluctuation from ideal
behaviour is studied. The action is thus taken accordingly.
 Preventive maintenance: this is done periodically and the
old or worn out machinery or the parts nearing their
specified EOH are replaced or refurbished.

 Breakdown maintenance: breakdown maintenance is

done in case any part or the machinery breaks down. The
machinery is isolated and overhauled. The system is
made to function normally by using stand-by equipments.

It also maintains the switch yard which consists of the entire

power supply system.
The switch yard consists of a step up transformer which steps
up the input voltage to the supply voltage of 220KV.
It consists of three load regulated lines, each of which is made
up of 3 bays. Thus a total 9 bays are there.

The switch yard and its block diagram

 INFORMATION AND TECHNOLOGY
DEPARTMENT

There are two types of IT departments in the power sector- the

corporate IT and the site IT. Corporate IT is installed at the
corporate offices of the corporation whereas site IT is
operational at the actual plant site.
Thus the site IT is operational at the Faridabad gas power
plant. The main functions and responsibilities of the department
are as stated below:

 It provides and maintains the PCs and the network in the

plant.

 It develops and maintains various local softwares like gate

pass and SMS alert softwares.

 The site IT is responsible to implement the applications of

the corporate within the plant.

 The IT department also maintains the SAP system of the

plant.

 The intranet system and the local mail of NTPC- lotusmail,

developed by IBM, are maintained by the IT department.

 It maintains the VSAT microwave space in transponder

from G01 along with the dish antennas and
communication transponders to transmit the data within
the plant.
 For external communication and to roll out SAP, high
bandwidth lease lines have been taken from BSNL. Also a
4mbps lease line has been taken from the corporate
centre for heavy data transmission and internet usage.

 The routers, modems, automatic switches are handled by

the department.

 It maintains the RJ45 connectors including the fibre optic

network used for video conferencing and broadcasting the
happenings at the corporate.

 The NTPC Faridabad is internally connected by Siemens

telephone exchange- Hi-path 4000. It handles the phone
data and also supports audio conferencing.

 IT department also maintains the Plant Information system

(PI system). It is a SAP related to power operations. It has
a comprehensive model which takes care of each and
every parameter of the plant equipments. It is interfaced to
each machine, takes the data and stores it in a database.
The data is then compiled and sent to the top
management at the corporate and head office.

 The IT department also maintains the server status

application which monitors the health of all the servers
within the site.
 CHEMISTRY (WATER TREATMENT)
DEPARTMENT
The water being fed into the plant must properly be treated and
de-mineralised for the proper functioning of the plant. The water
is demineralised because the minerals present in water cause
scaling and may react with the material it comes in contact with.
The various characteristics of water under which the treatment
process takes place are:

WATER TREATMENT CHARACTERISTICS

PHYSICAL BIOLOGICAL CHEMICAL

Turbidity Bacteria Cations

pH Microbes Anions

Conductivity

Taste/Odour
PHYSICAL: The physical treatment of water is done in the first
step. This is known as Pre-Treatment. The water from the
canals is first stored in the reservoir where the sedimentation
process takes place. From there it is sent to the filters where
coarse impurities are removed. It is then pumped to the water
softening plant where alum is added to it and all the physical
impurities get coagulated and are removed.

Water from Water

Sedimentation Gravity Sand
the main Decantation Filteration Softening
in the Reservoir Filteration
water source using ALUM

Process of physical treatment of water

BIOLOGICAL: Next step towards the Demineralisation of water

is removal of biological elements of water such as bacteria and
microbes. They are thus eliminated using chlorine. In order to
get a better stable compound, chlorine dioxide is used.

CHEMICAL: The water free from physical and biological

components is then sent to remove all the chemical compounds
from it.
For this purpose, the ion exchange process is used.

The water is first sent to the anion exchange resin to remove

the anions. Then the water is sent for degassing. It is then sent
 for the cation removal. This process is divided into two parts,
strong and weak acid cation removal.
It is then passed through the mixed ion exchange bed. The
water thus obtained is De-Mineralised water having the pH
ranging from 6.8-7.

Weak Strong
Dechlorination Anion Mixed Ion
Degassing Acid Acid DM
using Activated Exchange exchange
of Water Cation Cation Water
Carbon Filter Resin resin
Removal Removal

The process of chemical treatment of water

The ion exchange chambers

The water thus obtained has the following characteristics:

1. pH 6.8 to 7.0
2. Conductivity 0.1uS/m
3. TDS 20ppb
 CONTROL AND INSTRUMENTATION
DEPARTMENT
The Control & Instrumentation Department(C&I) is responsible
for the operation and of all the electronic sensors, actuators
and controllers besides maintaining the pressures,
temperatures, level and the flow in the various tanks, pipes and
also in the various heat exchangers present in the plant. It is
thus the brain of the plant.

The main functions of the C&I dept. at NTPC Faridabad are:

1. Measurement and display of various parameters.

2. To control the various parameters by Automatic feedback

controlling which involves the taking of decision based on
inputs from measurements by the processor.

3. Protection of various equipments (pumps, generators etc.)

and workers from hazards by automatically tripping a
cycle when hazardous conditions are reached.

4. Alarm generation in case of a mechanical or an electrical

failure.

The Faridabad plant has outsourced its automaton to various

companies on a Package Based Deal.
The C&I dept. besides also undertakes the modifications or
upgradation of its systems.

AUTOMATION AND CONTROL SYSTEM

The word automation is widely used today in relation to various
types of applications, such as office automation, plant or
process automation.
This subsection presents the application of a control system for
the automation of a process / plant, such as a power station. In
this last application, the automation actively controls the plant
during the three main phases of operation: plant start-up, power
generation in stable or put During plant start-up and shut-down,
sequence controllers as well as long range modulating
controllers in or out of operation every piece of the plant, at the
correct time and in coordinated modes, taking into account
safety as well as overstressing limits.
During stable generation of power, the modulating portion of the
automation system keeps the actual generated power value
within the limits of the desired load demand.
During major load changes, the automation system
automatically redefines new set points and switches ON or OFF
process pieces, to automatically bring the individual processes
in an optimally coordinated way to the new desired load
demand. This load transfer is executed according to pre-
programmed adaptively controlled load gradients and in a safe
way.
THE BENEFITS
The main benefits of plant automation are to increase overall
plant availability and efficiency. The increase of these two
factors is achieved through a series of features summarized as
follows:


Optimisation of house load consumption during plant
start- up, shut-down and operation, via:


Faster plant start-up through elimination of control errors
creating delays.

Faster sequence of control actions compared to manual
ones. Figures 1 shows the sequence of a rapid restart
 using automation for a typical coal-fired station. Even a
well- trained operator crew would probably not be able
to bring the plant to full load in the same time without
considerable risks.

Co-ordination of house load to the generated power
output.


Ensure and maintain plant operation, even in case of
disturbances in the control system, via:


Coordinated ON / OFF and modulating control
switchover capability from a sub process to a redundant
one.

Prevent sub-process and process tripping chain reaction
following a process component trip.


Reduce plant / process shutdown time for repair and
maintenance as well as repair costs, via:


Protection of individual process components against
overstress (in a stable or unstable plant operation).

Bringing processes in a safe stage of operation, where
process components are protected against overstress.

PROCESS STRUCTURE
Analysis of processes in Power Stations and Industry
advocates the advisability of dividing the complex overall
process into individual sub-processes having distinctly defined
functions. This division of the process in clearly defined groups,
termed as FUNCTIONAL GROUPS, results in a hierarchical
process structure. While the hierarchical structure is governed
in the horizontal direction by the number of drives (motorised
valves, fans, dampers, pumps, etc.) in other words the size of
the process; in the vertical direction, there is a distinction made
between three fundamental levels, these being the: -

Drive Level

Function Group Level

Unit Level.

To the Drive Level, the lowest level, belong the individual

process equipment and associated electrical drives.

The Function Group is that part of the process that fulfils a

particular defined task e.g., Induced Draft Control, Feed Water
Control, Blooming Mill Control, etc. Thus at the time of planning
it is necessary to identify each function group in a clear manner
by assigning it to a particular process activity. Each function
group contains a combination of its associated individual
equipment drives. The drive levels are subordinate to this level.
The function groups are combined to obtain the overall process
control function at the Unit Level.

The above three levels are defined with regard to the process
and not from the control point of view.

SWAS (Supply Water Analysis System)

It constantly monitors the various parameters of the

supply water.
CONTROL SYSTEM STRUCTURE

The primary requirement to be fulfilled by any control system

architecture is that it be capable of being organized and
implemented on true process-oriented lines. In other words, the
control system structure should map on to the hierarchy
process structure.

®
BHEL’s PROCONTROL P , a microprocessor based intelligent
remote multiplexing systemthat meets the requirement of
controlling the steam turbine. On the other hand CALIPUM-ST
controls the gas turbine.

SYSTEM OVERVIEW

The control and automation system used here is a

microcontroller based intelligent multiplexing system This
system, designed on a modular basis, allows to tighten the
scope of control hardware to the particular control strategy and
operating requirements of the process.
Regardless of the type and extent of process to control
provides system uniformity and integrity for:

 Signal conditioning and transmission.

 Modulating controls.

CONTROL AND MONITORING MECHANISMS

There are basically two types of Problems faced in a Power
Plant

Metallurgical

Mechanical

Mechanical Problem can be related to Turbines that is the max

speed permissible for a turbine is 3000 rpm , so speed should
be monitored and maintained at that level
Metallurgical Problem can be view as the maximum Inlet
o
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:

Employees

Machines

So the Parameters to be monitored are :


Speed

Temperature

Current

Voltage

Pressure

Eccentricity

Flow of Gases

Vacuum Pressure
 
Valves

Level

The C&I dept. uses various instruments in its functioning.

They can be broadly classified as:

1. Sensors
2. Controllers
3. Actuators

Sensors
1. Sensors are instruments used for measurement purposes.

2. They measure various parameters and convert them to

electrical output which is supplied to controllers.

3. This data is then displayed which aid the engineers make

the judicious decisions.

These sensors measure the following parameters:

1. Level of fluids in pipes and tanks.e.g. LVDT can be used

for this measurement.

2. Flow of fluids such as fuel steam etc. done by sensors

such as Venturimeters or Rotameters.

3. Pressure in tanks and pipes also can be measured

It’s done by sensors such as Gauges, Pressure Switches,
Capacitive Transducer etc.

4. Temperatures can be measured anywhere in the system.

Instruments such as Thermocouples and RTDs are used.
Controllers
These are devices which receive data from the sensors,
process it and give instruction to the actuators based on the
processed data. They are analogous to the human brain.

Various types of control systems used at NTPC Faridabad

are:
1. Single control system
This consists of a single processor which controls the entire
process. This system is not quite efficient as it draws large
amount of power and also if the processor fails then the entire
unit has to stop.

2. Distributed control system

This consists of various processors which are responsible for
various parts of the process and have a channel of
communication between them enabling them to work efficiently.
Such a system is more efficient and is favoured.
DCS is extensively used within the plant to control various
processes of the plant.

Actuators
Actuators are analogous to motor organs like hands or legs of
the body. Actuators are the instruments which are responsible
for carrying out control commands from the controller like
closing of a valve etc.
Actuators are of manly three types:

1. Pneumatic Actuators
These actuators carry out mechanical tasks using compressed
air. These are very accurate but are not very strong and get
damaged easily. The pressure in it is in the range of 3-15 psi.

2. Hydraulic Actuators
These use the pressure of compressed oil to perform their
tasks. These actuators are quite strong but lack a high degree
of accuracy.
 3. Electronic Actuators
These make use of electronic motors to perform their tasks.

MEASUREMENT OF VARIOUS PARAMETERS

1. PRESSURE MEASUREMENT
 Pressure switch:
A pressure switch is a form of switch that makes
electrical contact when a certain set pressure has been
reached on its input. This is used to provide on/off
switching from a pneumatic or hydraulic source. The
switch may be designed to make contact either on
pressure rise or on pressure fall.

They are categorised as:

Pneumatic
Uses of pneumatic pressure switches include:

 Switching off an electrically driven gas compressor when a

set pressure is achieved in the reservoir
  Switching off a gas compressor, whenever there is no feed
in the suction stage.
 in-cell charge control in a battery
 Switching on/off an alarm light in the cockpit of an aircraft
if cabin pressure (based on altitude) is critically low.

Hydraulic

Hydraulic pressure switches have various uses in automobiles,

for example:

 To switch on a warning light if engine oil pressure falls

below a safe level
 To switch on brake lights automatically by detecting a rise
in pressure in hydraulic brake lines
 In dust control systems (bag filter), a pressure switch is
mounted on the header which will raise an alarm when air
pressure in the header is less than necessary to gain or
decline energy beyond the set value
 To control automatic transmission torque converter lock-
up.

pressure swithes are used digital means of monitoring as

with being ON is referred as high and being OFF is as low.

All the monitored data is converted to either Current or Voltage

parameter.

The Plant standard for current and voltage are as under

Voltage : 0 – 10 Volts range

Current : 4 – 20 milliAmperes

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 %
The whole system used is SCADA based

ANALOG INPUT MICRO

INPUT 4-20 mA MODULE PROCESSOR

ALARM

DDCMIC control is used for this process.

Programmable Logic Circuits ( PLCs) are used in the process
as they are the heart of Instrumentation.

 Pressure Gauge
A flattened thin-wall, closed-end tube is connected at the
hollow end to a fixed pipe containing the fluid pressure to be
measured. As the pressure increases, the closed end moves in
an arc, and this motion is converted into the rotation of a
(segment of a) gear by a connecting link that is usually
adjustable. A small-diameter pinion gear is on the pointer shaft,
so the motion is magnified further by the gear ratio. The
positioning of the indicator card behind the pointer, the initial
pointer shaft position, the linkage length and initial position, all
provide means to calibrate the pointer to indicate the desired
range of pressure for variations in the behaviour of the Bourdon
tube itself. Differential pressure can be measured by gauges
containing two different Bourdon tubes, with connecting
linkages.
Bourdon tubes measure gauge pressure, relative to ambient
atmospheric pressure, as opposed to absolute pressure;
vacuum is sensed as a reverse motion. Some aneroid
barometers use Bourdon tubes closed at the ends (but most
use diaphragms or capsules, see below). When
the measured pressure is rapidly pulsing, such as when the
gauge is near a reciprocating pump, an orifice restriction in the
connecting pipe is frequently used to avoid unnecessary wear
on the gears and provide an average reading; when the whole
gauge is subject to mechanical vibration, the entire case
including the pointer and indicator card can be filled with an oil
or glycerine. Tapping on the face of the gauge is not
recommended as it will tend to falsify actual readings initially
presented by the gauge. The Bourdon tube is separate from the
face of the gauge and thus has no effect on the actual reading
of pressure. Typical high-quality modern gauges provide an
accuracy of ±2% of span, and a special high-precision gauge
can be as accurate as 0.1% of full scale.
In the following illustrations the transparent cover face of the
pictured combination pressure and vacuum gauge has been
removed and the mechanism removed from the case. This
particular gauge is a combination vacuum and pressure gauge
used for automotive diagnosis:

Indicator side with card and dial

Mechanical side with Bourdon tube

  The left side of the face, used for measuring manifold
vacuum, is calibrated in centimetres of mercury on its
inner scale and inches of mercury on its outer scale.
 the right portion of the face is used to measure fuel

pump pressure and is calibrated in fractions of 1 kgf/cm²

on its inner scale and pounds per square inch on its outer
scale.

 Pressure Transmitters

Pressure transmitters, a sub-group of pressure transducers,

feature additional reset and calibration options. With some
sensor types it is possible, for example, to re-set the measuring
span over large ranges. This calibration option is usually
referred to by such terms as “scale down”, “span reset” or “turn
down”. For instance, a transmitter with a measuring range of 0
to 400 psi and a range reset 1/10 can be calibrate to a
measuring range of 0 - 40 psi while still giving a full output
signal (4 - 20 mA, for example).

It is also possible to shift the zero point over a wide range and
to calibrate the damping of the output signal between 0 and 32
seconds. Smart transmitters such as Hart®, which have logging
capabilities, could be calibrated, tested and reset by the control
desk or hand terminals.

Capacitive transmitters
Transmitters are often used in process applications where they
can be combined with various chemical seals.

Discrete Control System:

A distributed control system (DCS) refers to a control system
usually of a manufacturing system, process or any kind of
dynamic system, in which the controller elements are not
central in location (like the brain) but are distributed throughout
the system with each component sub-system controlled by one
or more controllers. The entire system of controllers is
connected by networks for communication and monitoring.
DCS is a very broad term used in a variety of industries, to
monitor and control distributed equipment.

 Environmental control systems

 Traffic signals
 Radio signals
 Water management systems
 Oil refining plants
 Metallurgical process plants
 Chemical plants
 Pharmaceutical manufacturing
 Sensor networks
 Dry cargo and bulk oil carrier ships
 Electrical power grids and electrical generation plants
 2. TEMPERATURE MEASUREMENT:
Temperature Measurement System

Field
Electrical Static
system

RTD Mercury Bimetallic

Thermocouple Alcohol

Gas

Vapour

Electrical
 Resistance thermometer
Resistance thermometers, also called resistance temperature
detectors (RTDs), are sensors used to measure temperature by
correlating the resistance of the RTD element with temperature.
Most RTD elements consist of a length of fine coiled wire
wrapped around a ceramic or glass core. The element is
usually quite fragile, so it is often placed inside a sheathed
probe to protect it. The RTD element is made from a pure
material whose resistance at various temperatures has been
documented. The material has a predictable change in
resistance as the temperature changes; it is this predictable
change that is used to determine temperature.
As they are almost invariably made of platinum, they are often
called platinum resistance thermometers (PRTs). They are
slowly replacing the use of thermocouples in many industrial
applications below 600 °C, due to higher accuracy and
repeatability. Common RTD sensing elements constructed of
platinum copper or nickel have a unique, and repeatable and
predictable resistance versus temperature relationship (R vs T)
and operating temperature range. The R vs T relationship is
defined as the amount of resistance change of the sensor per
degree of temperature change.

 THERMOCOUPLE:
A thermocouple is a device consisting of two different
conductors (usually metal alloys) that produce a voltage,
proportional to a temperature difference, between either ends
of the two conductors. Thermocouples are a widely used type
of temperature sensor for measurement and control and can
also be used to convert a temperature gradient into electricity.
They are inexpensive interchangeable, are supplied with
standard connectors, and can measure a wide range of
temperatures. In contrast to most other methods of temperature
measurement, thermocouples are self powered and require no
external form of excitation. The main limitation with
thermocouples is accuracy, specifically, system errors of less
than one degree Celsius(C) can be difficult to achieve.
Any junction of dissimilar metals will produce an electric
potential related to temperature. Thermocouples for practical
measurement of temperature are junctions of specific alloys
which have a predictable and repeatable relationship between
temperature and voltage. Different alloys are used for different
temperature ranges. Properties such as resistance to corrosion
may also be important when choosing a type of thermocouple.
Where the measurement point is far from the measuring
instrument, the intermediate connection can be made by
extension wires which are less costly than the materials used to
make the sensor. Thermocouples are usually standardized
against a reference temperature of 0 degrees Celsius; practical
instruments use electronic methods of cold-junction
compensation to adjust for varying temperature at the
instrument terminals. Electronic instruments can also
compensate for the varying characteristics of the thermocouple,
and so improve the precision and accuracy of measurements.
Thermocouples are widely used in science and industry;
applications include temperature measurement for kilns, gas
turbine exhaust, diesel engines, and other industrial processes.

Certain combinations of alloys have become popular as

industry standards. Selection of the combination is driven by
cost, availability, convenience, melting point, chemical
properties, stability, and output. Different types are best suited
for different applications. They are usually selected based on
the temperature range and sensitivity needed. Thermocouples
with low sensitivities (B, R, and S types) have correspondingly
lower resolutions. Other selection criteria include the inertness
of the thermocouple material and its magnetic properties.

K type:
Type K (chromel {90 percent nickel and 10 percent chromium}
– alumel {95% nickel, 2% manganese, 2% aluminium and 1%
silicon}) is the most common general purpose thermocouple
with a sensitivity of approximately 41 µV/°C, chromel positive
relative to alumel. It is inexpensive, and a wide variety of
probes are available in its −200 °C to +1350 °C / -328 °F to
+2462 °F range. Type K was specified at a time when
metallurgy was less advanced than it is today, and
consequently characteristics may vary considerably between
samples. One of the constituent metals, nickel, is magnetic; a
characteristic of thermocouples made with magnetic material is
that they undergo a deviation in output when the material
reaches its Curie point; this occurs for type K thermocouples at
around 350° C.

Field system
 Manometer Elements
The manometers are mostly used in laboratory for
calibration purposes as these are the fundamental type of
instruments. At site they are mainly used for test purposes,
in the low ranges 0-1000 mm with mercury as manometers
liquid maximum being.
If one end is sealed, then the manometer can be used for
absolute pressure measurement. If the area of one of the
limb is made considerably greater then the other, then the
measurement of the differential pressure is represented by
the height of the liquid column in the smaller tube with
negligible error. Such system is called the single limb
manometer or cistern manometer since the larger area pipe
is in the form of a metal cistern. The manometer liquid
normally used is water. Sometime coloured water is used to
distinguish the column. The other liquids used are:

a. Transformer oil having specific gravity 0.864

b. Mercury having specific gravity 13.56
c. Blended Paraffin liquid.
Static
 Bimetallic strip
The expansion of solids is utilized by means of bimetallic strip
to measure temperatures. Two or more layers of metallic alloys
having different co-efficient of thermal expansions are coiled in
the form of (a) spiral (b) helical or (c) multiple helical depending
upon the range temperature.
One end of the coil is fixed on to the bulb to be used as a test
body and the other and free to move carrying the pointer over a
scale calibrated in degrees.
A simple bimetallic strip composed of a layer of brass (high
expanding material) and a layer of invar (low expanding
material) will deflect when subjected to a change of
temperature and if the strip is coiled its angular motion will be
given by CTL/t where C=length of strip in CMS and t=thickness
in CMs Fig .36 shows the typical bimetallic gauge.
 3.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.

For Digital measurements Flap system is used.

For Analog measurements we can use the following methods :


Flowmeters

Venurimeters / Orifice meters

Turbines

Massflow meters ( oil level )

Ultrasonic Flow meters

Magnetic Flowmeter ( water level )

Selection of flow meter depends upon the purpose , accuracy

and liquid to be measured so different types of meters used.
Turbine type are the 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), the theoretical pressure drop at
2 2
the constriction would be given by (ρ/2)(v2 - v 1 ).

And we know that rate of flow is given by:

Flow = k √ (D.P)

Where DP is Differential Presure or the Pressure Drop.

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.
Motorised valves – these valves are controlled by electric
motors.

4-20mA ELECTRICAL TO 3-15 PSI

DIGITAL CONTROL PNEUMATIC
SYSTEM POSITION CONTROL
CONVERTOR

VALVES

Valve position control mechanism

An electrical to pneumatic convertor