DAMODAR

VALLEY CORPORATION
DSTPS, ANDAL

NAME OF THE STUDENT: KARANJI ROY

UNIVERSITY ROLL NO:22020002013007

SEMESTER: 7TH

DURATION OF THE TRAINING:

4/07/2022-18/07/2022

SUBMISSION: 18/07/2022
 ABSTRACT
The industrial training program duration is of two weeks. During these days I am introduced
to different plants and how the whole process is conducted. Significance of the different
plants is described by the guides. I am familiarized with the handling processes of coals, ass
and of water packages. The use of different instruments and also all the process monitoring
by the control is being observed by me. The Integration of various sensors to measure
different parameters like temperature, pressure, flow, valves and pH and level is also
observed by me.
 ACKNOWLEDGEMENT

We would like to express our profound gratitude to all those who have given us this
opportunity to undergo this summer vocational training.

We are extremely grateful to Mr. Akshay Kumar who is Deputy Chief Engineer and also to
Mr. Falguni Dewanji who is Assistant Chief Engineer of Control and Instrumentation
Department. They have been the sole motivator and a source of inspiration for us to carry out
the necessary proceedings for the training. We are also highly obliged to all the respected
faculty members, staff and the co-trainees for their constant help and encouragement.

Last but not the least, a big thank you to Damodar Valley Corporation, Durgapur Steel
Thermal Power Station at Andal, for giving us this esteemed privilege to acquire knowledge
about the industrial methodology of work.

We will really cherish this experience of industrial training throughout our life and hope that
this will count a lot more in our future career.

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TABLE OF CONTENTS

Chapter No. Topic Page No. ` 1 Introduction 1 2 Brief about DVC 2 3 Details about Different Plants of
DVC

Main Plant 3

Coal Handling Plant 9

Ash Handling Plant 11

DM Plant 13

Water Package 14

Control Room 15

Instrumentation Observed 16

Switchyard 17

4 Conclusion 18 III

CHAPTER - 01

INTRODUCTION

Damodar Valley Corporation came into existence on 7th July 1948. Over time, the corporation
has pinnacle in the sector of power generation in the eastern region around the turbulent
flowing Damodar River.

The main purpose of a power plant is to generate power or electricity. Here in a power plant
the electrical energy is converted into a series of different energies. First chemical energy
changes to thermal energy by coal combustion, after that thermal energy changes to
mechanical energy by turbine torque. Later mechanical energy changes to electrical energy
using generator action. As a result electricity generated from the different types of process but
the achieved voltage from generator output is very low voltages, so the step up transformer is
used to transmit the power through high voltages transmission line.

Duration: - From 4th July, 2022 to 18th July, 2022.

For the industrial program, a two weeks of industrial tour is given by DVC, Andal.

They describe the whole process day by day. Each day the designated guide takes the groups
to each plant to show the working processes. Because we have done the training under the
Control and Instrumentation department. Our training mainly focused on learning about the
control room and how it is monitoring and controlling whole processes. How the different
types of sensors and instruments are used to sense different parameters and depending on the
outputs, PLC and SCADAs are controlling the settings should be to take the steps according
to the circumstances.

CHAPTER – 02

BRIEF ABOUT DAMODAR VALLEY CORPORATION

The Damodar Valley Corporation (DVC) is an Indian governmental organization which

operates in the Damodar River area of West Bengal and Jharkhand states of India. The
corporation operates both thermal power stations and hydel power stations under the Ministry
of Power, Government of India. DVC is headquartered in the city of Kolkata, West Bengal,
India.

DVC emerged as a culmination of attempts made over a whole century to control the wild and
erratic Damodar River. The Valley has been ravaged frequently by the floods at varying
intensities. Serious floods occurred in 1730, 1823, 1848, 1856, 1882, 1898, 1901, 1916, 1923,
1935 & 1943. The river spans over an area of 25,235 sq. km covering the states of Bihar (now
Jharkhand) & West Bengal. The catastrophe caused by the 1943 flood led to serious public
indignation against the Government of Bengal appointed a board of Enquiry titled “Damodar
Flood Enquiry Committee” with the Maharaja of Burdwan and the noted physicist Dr.
Meghnad Saha as a members for suggesting remedial measures.

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CHAPTER – 03

DETAILS ABOUT DIFFERENT PLANTS OF DVC

MAIN PLANT

The components of the main plant are: -

❖ Boiler- To generate steam at high pressure and temperature.

Stream is generated from De-Mineralized water by heat addition to DM water at
constant pressure and temperature.
 Figure 3.0: Boiler

Boiler description: -

● Top supported, fusion welded

● Vertical water-tube boiler
● Controlled Circulation
● Four-corner tilting tangential firing

Boiler Mountings: -

● Pressure Gauges: For measuring pressures at various points.

● Valves: For safety and to maintain unidirectional flow.
● Water Level Indicator: For optimum running of boiler.
● Long Retractable Soot Blower: For cleaning soot from boiler’s inner
surfaces.

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❖ The Draft System: -

Combustion air Flue Gases

Figure 3.1: The Draft System

● To combust of the air.

● To evacuate the flue gases.
● To overcome the loss due to flow.

Major Fans in Boiler Draft System:

1. Primary Air Fans: - Primary air fans or PA fans are high-pressure fans, used in the
boiler power plants to supply the air for transportation of coal directly from the
 Pulverizer to the furnace. PA fans give positive pressure upstream of the coal
Pulverizer and handle relatively clean air.
2. Forced Draft Fans: - FD Fans supply the air necessary for fuel combustion by
pushing air through the combustion air supply system and into the furnace. 3. Induced
Draft System: - ID Fans is provided to maintain a negative pressure in the furnace by
sucking the products of combustion from it with a slight positive pressure at the
discharge end of the bottom of the boiler.

Boiler Accessories: -

❖ Air Preheater: APH is the last heat exchanger in the boiler flue gas circuit. To
achieve maximum boiler efficiency, maximum possible useful heat must be removed
from the gas before it leaves the APH. However, a certain minimum temperature has
to be maintained in the flue gas to prevent cold end corrosion.

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Functions of Air Preheater: -

1. The air is preheated by flue gases to ensure complete combustion of even low grade
fuel like lignite.
2. The combustion air if preheated is economically feasible.
3. The process dries the pulverized coal.
4. It increases the initial combustion air temperature and increases the boiler
efficiency.

Figure 3.2: Air Preheater

Advantages: -

1. Hot air improves stability of combustion.

 2. High heat transfer rate in the furnace, hence lesser heat transfer area is required. 3.
Lesser unburnt fuel particles are present in flue gas. Intensified combustion provides
faster load variation and fluctuation.
4. In case of pulverized coal combustion, hot air is used to heat the coal initially and to
transport the pulverized coal to burners.
❖ Fuel System- It consists of a) Fuel oil system b) Oil burners c) Coal mills and feeders.

Purpose:

i) To establish the initial boiler light up.

ii) To support the furnace flame during load operation.

Fuel oil system: It consists of Fuel oil pumps, Oil heaters, Filters, Stream tracing lines. 5

Two types of oil used:

i) LDO (light diesel oil): Viscosity is less and is costly.

ii) HFO (heavy fuel oil): Viscosity is more and is cheaper.
❖ Atomization- The process involves breaking of fuel into fine particles ready to mix
with combustion air. Oil should be divided up into small particles for effective
atomization.
The advantages of atomization are:
i) Complete combustion is assured by the ability of the small particles to penetrate
turbulent combustion.
ii) Atomizing burners can be used for heavier grades of oil.
iii) It can be used for large applications using its larger capacity range. ❖
Mill Dampers and Air System
i) PF temperature to be maintained at 900°C.
ii) All shut off valves should be kept wide open during operation.
iii) Mill should be kept clean and no dust entry is allowed.
iv) Low Primary air flow will cause unstable flame and high flow will result in high
mill rejection.
❖ Boiler Drum
i) Separation of water and steam and thus maintaining steam purity. ii)
Provides water storage.
iii) Chemical dosing and sludge removal.
iv) Supplying water wall tubes and steam to saturated steam tubes.

Other Accessories:

o Economiser: Feed water is heated by the outgoing flue gases before entering the
 boiler drum.
o Super heaters: Steam is heated to higher temperature to ensure dryness fraction
remains above 0.8.
o Re-heaters: Steam is reheated between HPT and IPT and again between IPT and
LPT.

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❖ Turbine- 3 turbines : HP, IP, and LP
● High Pressure Turbine (HPT) – 17 stages
● Intermediate Pressure Turbine (IPT) – 12 x 2 stages
● Low Pressure Turbine (LPT) – 6x2 stages
● 3000 RPM
● Heat Rate: 1944.4 kcal/kWh
❖ Generator and Exciter- Generates electrical power by the interaction of the rotating
magnetic fields of the stator and rotor.
● kW: 500000
● Speed: 3000 RPM
● kVA: 588000
● Frequency: 50 Hz
● P. F.: 0.85 Lag Coolant: H2 and H2O
● Made at BHEL, Haridwar
● Brushless excitation system

Figure 3.3: Turbine

▪ Turbine Condensate System: The steam after condensing in the condenser known as
condensate is extracted out of the condenser hot well by condensate pump and taken
to the deaerator through drain coolers and series of LP heaters.
 ▪ D/A Level Controller: To control the level of D/A.

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▪ Drain cooler: To blend the cold water from the humidifier condensate of steam in the
dispersion system.
▪ LPH: To increase the temperature of condensate.
▪ Deaerator: To remove the dissolved gases from feed water to prevent corrosion.
❖ Feed Water System-
● The main equipment coming under the feed under system are boiler feed, three
per unit of 50% capacity each located in the ‘0’ meter level in the TG bay. ● High
Pressure Heaters, normally three in number and are situated in the TG bay, BFP.
The boiler feed pump system consists of three boiler feed pump sets one is motor
driven (MDBFP) and other two are steam driven (TDBFP) which takes suction
from the deaerator and discharge the feed water to series of HP heaters,
economiser and finally to boiler drum.

Figure 3.4: Boiler Feed Pump

❖ HP Heaters- These are regenerative feed water heaters operating at high pressure and
located by the side of the turbine. These are generally vertical type and turbine bleed
steam pipes are connected to them. HP Heaters are connected in series on the feed
waterside and by such arrangement the feed water, after the feed pump enters HP
heaters. The steam is supplied to these heaters from the bleed point of the turbine
through motor operated valves. These heaters have a group bypass protection on the
feed waterside.
❖ Steam Turbine- A steam turbine is a mechanical device that extracts thermal energy
from pressurized steam and converts it into useful mechanical work.

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COAL HANDLING PLANT

The huge amount of coal is usually supplied through railways. A railway siding line is taken
into the power station and the coal is delivered in the storage yard. The coal is unloaded from
the point of delivery by means of wagon tippler or BOBR (Bottom Open Bottom Release).
The coal is taken from the unloading site to dead storage by belt conveyors. The belt delivers
the coal to 0m level to the penthouse boiler and further moves to transfer points.

The transfer points are used to transfer coal to the next belt.

The belt further elevates the coal and it reaches the crusher through the belt. In the crusher a
high speed 3-Phase Induction Motor is used to crush the coal to a size of 50mm so as to be
suitable for the milling system. Coal rises from the crusher house and reaches the dead
storage by passing through the transfer point.

Figure 3.5: Process of Coal Handling Plant

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Equipment used in a coal handling plant

1. Pull Chord Switch: A series of such switches are arranged in series at a 1 m

distance on the side of the conveyor belt. The power supply to the rotor of the
conveyor belt is established only if all switches in series are connected.
2. Vibrating Feeder: The coal stored in a huge hub is collected on the belt through
vibrations created by the vibrating feeder.
3. Flap Gates: These are used to channelize the route of coal through another belt
in case the former is broken or unhealthy. The flap gates open let the coal pass
and if closed stop its movement.
4. Magnetic Separator: These are used to separate the ferrous impurities from the
coal.
 5. Metal Detector: This detects the presence of any ferrous and non-ferrous metal
in the coal and sends a signal to a relay which closes to seize the movement of
the belt until the metal is removed. It basically consists of a transmitter and a
receiver.
The transmitter consists of a high frequency oscillator, which produces an
oscillation of 1500 Hz at 15V. The receiver receives this frequency signal. If
there is any presence of metal in the coal. Then this frequency is disturbed and
a tripping signal is sent to relay to stop the conveyor belt.
6. Belt Weightier: It is used to keep an account of the tension on the belt carrying
coal and it moves accordingly to release tension on the belt.
7. Stacker and Reclaimer: Reclamation is a process of taking coal from the dead
storage for preparation or further feed reclaim hoppers. This is accomplished
by belt conveyors.

Figure 3.6: Stacker and Reclaimer

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ASH HANDLING PLANT

Two different types of ash are: (i) Coarse Ash & (ii) Fly Ash.

We can collect ash as a form of Wet Ash (Water + Ash) and Dry Ash (Air + Ash). We collect
it from four different sides. Those are: -

1. Bottom Ash Hopper- Bottom Ash is collected as wet or dry form.

o For wet ash
After combustion the more weighted ash gets down to the water (stored at bottom
ash hopper) and becomes a clinker which is made pulverized by a clinker grinder.
After that these pulverized clinkers are sent to the ash slurry sump through the
pipes by water coming from the bottom ash high pressure pump.
 Figure 3.7: Bottom Ash Hopper
o For dry ash
Dry Bottom Ash collection system after clinker grinder collects ash to silo through
a transport mechanism for further transport through the road system.
2. Economiser- Here at economiser there are four hoppers. Flue gas flows through
economiser and the weighted gas gets down to the hopper where water mixed with the
ash and then the wet ash goes to the ash slurry sump through pipe as well as drain by
water coming from fly ash high pressure pump.

Figure 3.8: Economiser

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3. Electrostatics Precipitator- To remove fly ash from flue gas electrostatic precipitators
are used. They have collection efficiency 99.5%. The efficiency depends on various
parameters such as velocity of flow, quantity of gas, resistivity of ash, voltage of
fields, temperatures etc. We can collect ash from ESP in wet ash form as well as in
Dry ash form.
 Figure 3.9: Electrostatics Precipitator

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DM PLANT

ACF → SAC → DGT → DGB PP → SBA → MB → UFFT → UFF PP → UFSKID →

UFPT PP → DMST

❖ Activated Carbon Filter:

● To absorb residual chlorine & organic matter.
● To arrest finer dirt particles if present in filtered water.
❖ Strong Acidic Cation Exchanger:
● To convert the salts present in filtered water to their
corresponding acids by arresting the cations.
 ❖ Degasser:
● To decrease the load on SBA by removing CO2 Gas from the
effluent of SAC.
❖ Strong Basic Anion Exchanger:
● To pick up anions from degassed water and to produce
deionized water.
❖ Mixed Bed:
● To take care of any care over due to leakage from SBA.
● To act as a safeguard against silica slip.
❖ Ultrafiltration SKID:
● To remove colloidal silica to provide ultra-pure water.
❖ DM Water Storage Tank:
● To provide make up water for the steam cycle.
● To provide make up water for De-mineralized cooling water.

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WATER PACKAGE

Raw water supplies are required for three main purposes: -

o To provide make-up water to the water steam cycle.

o For cooling of the steam for reuse as condensate.
o General Domestic use.

Requirement of pre-treatment of Raw Water: To remove impurities like organic matter

turbidity and microorganism from raw water which otherwise would adversely affect
subsequent water treatment process.

Aeration
o To remove undesirable gases like H2S, CO2 etc.
o To oxidize Fe++& Mn++.
o To facilitate the removal in the clarifier.
 o To degrade other organic matter.
Pre-Chlorination
o To kill microorganisms.
o To destroy organic matter.
Clarifier
o To remove colloidal silica.
o To remove impurities which are in coarse suspension.
Filtration
o To arrest finer dirt particles if present after coagulation.

Requirement of demineralization of Filtered Water:

o To avoid scale or deposit formation on heat transfer

surfaces.
o DM Water is completely non-conductive so there is no
chance of earth fault during stator cooling.

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CONTROL ROOM

▪ Programmable Logic Controls (PLC): A PLC is a digital computer used for

automation of typical industrial electromechanical processes, such as control of
machinery on factory assembly lines. The logic control is used for dedicated functions
not distributed work.
▪ Distributed Control System (DCS): A DCS is a control system for a process or plant
where controls are distributed throughout the system. Here a hierarchy of controllers
are connected by communication networks for command and monitoring.
▪ Supervisory Control and Data Acquisition (SCADA): It is a system operating with
coded signals over communication channels so as to provide control of remote
equipment (using typically one communication channel per remote station). The
control system may be combined with a data acquisition system by adding the use of
coded signals over communication channels to acquire information about the status of
the remote equipment for display for recording functions. The output command is
given to various valves and controls and the corresponding parameter readings are fed
as input to the control room for examination.
 Figure 3.10:

PLC Block Diagram Figure 3.11: Control Room

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INSTRUMENTATION OBSERVED

▪ Pressure Measurement:
1. DP Transmitter
2. Radar Type Transmitter
3. Bourdon Pressure Gauge
4. LVDT

▪ Level Measurement:
1. Radar Type Transmitter
2. Ultrasonic Transmitter
3. Float Based Capacitive Type

▪ Flow Measurement:
1. Aerofoil
2. Orifice
3. Rotameter

▪ Temperature Measurement:
1. RTD
2. Thermocouple

▪ Valves:
1. Globe Type
 2. Butterfly Type

▪ pH Measurement:
1. pH meter

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SWITCHYARD

Figure 3.12: Switchyard

The switchyard is a junction connecting the transmission and distribution system to the power
plant.

The function of Switchyard is to deliver the generated power from the power plant at desired
voltage level to the nearest grid.

Bus-Bar is used to interconnect the loads and sources of electrical power. It connects the
incoming and outgoing transmission lines. It also connects the generator and main
transformer in the power plant.

Bus-Bars are either flexible or rigid. Flexible bus-bars are made of ACSR conductors and are
supported by disc insulator strings on both sides with the gantries. Rigid bus-bars are made up
of Aluminum tubes.

In DSTPS Andal, One and half breaker system is used.

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CHAPTER - 04

CONCLUSION

I am allotted two weeks of plant familiarization and orientation program of Durgapur Steel
Thermal Power Stations (DSTPS), DVC at Andal. During these two weeks I came across
various shops and departments and learned the process flow diagram of DSTPS, Andal as
well as the material and process flow of each department. I also came to know a little about
the working culture prevailing in the plant. The practical experience I have gathered during
the overview training of this thermal power plant in two weeks will be very useful as a
stepping stone in building a bright professional career in future.

It gave me a large spectrum to utilize theoretical knowledge and to put it into practice.

The trouble shooting activities in operation and decision making in case of crisis made me
more confident to work in the industrial atmosphere.

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