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TABLE OF CONTENTS

1- Acknowledgement
2- Abstract
3- Brief description of Tanda Thermal Power Plant
4- Production of Electricity
5- Basic power plant cycle
6- Description of thermal plant
7- Different cycles of a power plant
8- Important equipment of plant
9- Control and instrumentation unit
10 Future prospects of NTPC Tanda

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BRIEF DESCRIPTION OF TANDA THERMAL

PROJECT

Geographical location:-

The Tanda Thermal Power Project is located about 70 kms from Ayodhya.
The nearest rail ahead is Akbarpur (now called as Ambedkarnagar). The
project lies in the Ambedkarnagar district and is about 22kms from the
nearest railway station.

The complete project is situated on the bank of Saryu River. The climate
conditions are quite favourable with greenery all around.

Features:-

• The installed capacity is 4 X 110 MW

• The new plant have capacity of 6 X 660 MW.

The water requirement of the station is met from the Saryu River through
Mehripur pumping Station constructed for feeding Mehripur Pump Canal.
The coal linkages for the station have been provided from North Karnpura &
BCCL. The power generation is evacuated through 220kV feeders connected
to Sultanpur (2 feeders), Basti & Gorakhpur (1 each) 220kV substations.

The total area of the power house including colony is 235 hectares and the
land for ash disposal is 170 hectares.

✓ The main plant equipments like boiler, turbine and generator have been
supplied by M/s BHEL
✓ Generator-transformer has been supplied M/s NGEF
✓ CHP(Coal Handling Plant) has been supplied by M/s TRF
✓ Cooling Towers by Paharapur Cooling Towers

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✓ C&I(Control & Instrumentation sets) have been supplied by M/s ILK

✓ DM(De-mineralized) plant has been set up by M/s. WATCO,
Hyderabad

The designed boiler efficiency, turbine heat rate and unit heat rate are 84.7%
and 2172.8kcal/kWh & 2565.3kcal/kWh respectively.

The designed HHV of coal is 3850kcal/kg and the boiler is designed to work
at worst quality of coal having HHV of 3400kcal/kg.

Tanda plant PLF:-

2000 2006 2008

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PRODUCTION OF ELECTRICITY
The means and steps involved in the production of electricity in a coal-fired
power station are described below.

The coal, brought to the station by train or other means, travels from the coal
handling plant by conveyer belt to the coal bunkers, from where it is fed to
the pulverizing mills which grinds it as fine as face powder. The finely
powdered coal mixed with pre-heated air is then blown into the boiler by fan
called Primary Air Fan where it burns, more like a gas than as a solid in
convectional domestic or industrial grate, with additional amount of air
called secondary air supplied by Forced Draft Fan. As the coal has been
grounded so finely the resultant ash is also a fine powder. Some of this ash

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binds together to form lumps which fall into the ash pits at the bottom of the
furnace. The water quenched ash from the bottom of the furnace is conveyed
to pits for subsequent disposal or sale. Most of ash, still in fine particles form
is carried out of the boiler to the precipitators as dust, where it is trapped by
electrodes charged with high voltage electricity. The dust is then conveyed
by water to disposal areas or to bunkers for sale while the cleaned flue gases
pass on through ID Fan to be discharged up the chimney.

Meanwhile the heat released from the coal has been absorbed by the many
kilometres of tubing which line the boiler walls. Inside the tubes is the boiler
feed water which is transformed by the heat into the steam at high pressure
and temperature. The steam super-heated in further tubes (Super Heater)
passes to the turbine where it is discharged through the nozzles on the
turbine blades. Just the energy of the wind turns the sail of the wind-mill, so
the energy of the steam, striking the blades, makes the turbine rotate.

Coupled to the end of the turbine is the rotor of the generator – a large
cylindrical magnet, so that when the turbine rotates the rotor turns with it.
The rotor is housed inside the stator having heavy coils of copper bars in
which electricity is produced through the movement of the magnetic field
created by the rotor. The electricity passes from the stator winding to the
step-up transformer which increases its voltage so that it can be transmitted
efficiently over the power lines of the grid.

The steam which has given up its heat energy is changed back into water in
the condenser so that it is ready for re-use. The condenser contains many
kilometres of tubing through which the colder is constantly pumped. The
steam passing around the tubes looses the heat and is rapidly changed back
to water. But the two lots of water (i.e. boiler feed water & cooling water)
must NEVER MIX. The cooling water is drawn from the river, but the boiler
feed water must be absolutely pure, far purer than the water we drink, if it is
not to damage the boiler tubes. Chemistry at the power station is largely the
chemistry of water.

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To condense the large quantities of steam, huge and continuous volume of

cooling water is essential. In most of the power stations the same water is to
be used over and over again. So the heat which the water extracts from the
steam in the condenser is removed by pumping the water out to the cooling
towers. The cooling towers are simply concrete shells acting as huge
chimneys creating a draught (natural/mechanically assisted by fans) of air.
The water is sprayed out at the top of towers and as it falls into the pond
beneath it is cooled by the upward draught of air. The cold water in the pond
is then circulated by pumps to the condensers. Inevitably, however, some of
the water is drawn upwards as vapours by the draught and it is this which
forms the familiar white clouds which emerge from the towers seen
sometimes.

Why bother to change stem from the turbine back into water if it has to be
heated up again immediately? The answer lies in he law of physics which
states that the boiling point of water is related to pressure. The lower the
pressure, the lower the temperature at which water boils. The turbine
designer want as low boiling point of water as possible because he can only
utilize the energy of the steam – when the steam changes back into water he
can get NO more work out of it. So a condenser is built, which by rapidly
changing the steam back into water creates a vacuum. This vacuum results in
a much lower boiling point which, in turns, means he can continue getting
work out of the stem well below 100 degree Celsius at which it would
change into water.

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The above figure shows the ranking cycle graph which is used in a power
plant. The paths shown below the figure represents the complete the whole
steam and heat cycle as followed in different operation cycles of a power
plant.

BOILER: 4 no of radiant dry bottom natural circulation, vertical water

tube boiler with single reheat 380ton/hr of steam pressure 160kg per
square cm at 540 degree centigrade of temperature.
TURBINE AND TURBO GENERATOR: 4 no. of 110 MW each.
WATER TREATMENT PLANT:4x30 ton/hr capacity.

OUTER SUBSTATION:
a) Power Transformer: 4 no. of 125 MVA 11/220 kVA.
b) Reverse Transformer: 2 no. of 30/20/10 MVA
220/66/33 kVA.

RATED PARAMETERS:
Rated parameter related to output: 110 MW.
Economical Output: 95 MW.
Rated Speed: 3000 rpm.
Rated temp. of steam before steam valve: 540*C. Max.
temperature of steam before stop valve: 543*C. Rated
temperature of steam before MP casing: 540*C.Max.
temperature of steam before MP casing: 543*C.
Rated pressure of steam just before stop valve:130 atm. Max.
pressure of steam just before stop valve: 136 atm. Normal
pressure of steam before MP casing: 31 atm.
Max. pressure of steam just before stop valve: 37 atm.
Cooling water temperature: 32*C.

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SYSTEM OF THE TURBINE:

2 Stop valve, one on either side of HP casing.

4 Control valves, 2 on either side of HP casing.
2 Stop valves, one on either side of MP casing.
2 Interceptor valves, one on either side of MP casing.
2 Row circuit wheels, 8 moving wheel in HP cylinder.
8 Non regulated extraction and one reheat.
Weight of HP rotor (approx.): 5,500 kg.
Weight of MP rotor (approx.): 11,000 kg.
Weight of LP rotor (approx.):24,000 kg.
Direction of rotation:
Clockwise looking at the turbine from the pedestal 1.
Barring speed: 62 rpm.

DESCRIPTION OF THERMAL PLANT

The plant is in fact designed on the modern concept of unit system. Each of
the turbo-generator is connected to its individual steam generating plant. The
steam turbine has inlet steam pressure of about 130kg/cm2 and super heat
type with a reheat temperature of 540 0C. Regenerative feed heating with 8
stages heaters have been adopted. There are two high pressure feed water
heaters connected with the exhaust of the H.P cylinder and the second one
from an extraction of I.P cylinder.

Constant pressure de-aeration is adopted for de-aeration and is fed from

auxiliary system header of the plant which maintains the de-aeration pressure
of 6kg/cm2 under all load conditions.

There are five low pressure heaters – two connected to the IP (Intermediate
Pressure) heaters. The heat input from the grand steam condenser and the
ejector condenser is also recovered to improve the cycle efficiency. Drip
pump is also used to pump the drain from the 3 rd LP (Low Pressure) heater
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back to the condensate system. This also adds to the efficiency of the system.
Drains from various stages of steam turbine are treated so that the maximum
thermodynamics benefit is derived.

The plant is also provided with automatic control features. The operation of
the Coal Handling, Ash Handling, Water treatment Plant, River water Intake
pump is provided with remote as well as local manual control features to
cope with the requirements of such large units.

DIFFERENT CYCLES OF A POWER PLANT

For proper functioning of a power plant, its working operation has been
divided into following main operation cycles.

Steam cycle
Feed water cycle
Condensate water cycle
Primary air cycle
Flue gas cycle
Secondary air cycle

Steam cycle: -
This cycle basically deals with the flow of steam at different pressure and temperature
to different turbines namely HP, MP and LP turbines which are connected to the
generato

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Steam coming out from super heater at 540degree C and 139kg per square
cm. Three cylinders of 2 set of main stop and governing valve arrangement
on either side of HP casing and each set consist of one stop valve and 2
governing valve assembling series. The steam from the boiler is admitted the
reheater where it heated at original temp. The reheated steam is taken to IP
casing through combined stop and interceptor valve arrangement at either of
IP casing. The exhaust from the IP casing has taken directly the LP casing.
The steam expanded in the LP turbine to a very low blade pressure which is
maintained by the condenser below atmospheric pressure about 3% of
makeup water is required to condensate the losses of cooling water due to
evaporation in cooling tower. Finally steam exhausted by LP turbine is
condensed in the surface type condenser type cooling water following
through a large no. of tubes. The HP, IP &LP turbine coupled in series and
mechanical power generated from steam transmitted to generator.

Feed water cycle: - this cycle deals with the flow of water to boiler feed
pump from feed storage tank, which is later fed to the boiler drum passing
through high pressure heater and economizer

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This system plays an important role in the supply of feed water to the boiler
at requisite pressure and steam/water ratio. This system starts from boiler
feed pump to feed regulating station via HP heaters
Boiler feed pump: this pump is horizontal and barrel design driven by an
electric motor through a hydraulic coupling. All the bearings of the pump
and motor are forced lubricated by oil lubricating system. The feed pump
consists of pump barrel into which is mounted the inside starter, together
with rotor. Water cooling and oil lubricating are provided with their
accessories. The brackets of the radial bearing of the suction side and the
radial and thrust bearing of the discharged side are fixed to low pressure.
High pressure heater: these are regenerative feed water heater operating at
high pressure and located by the side of turbine. It is connected in series on
feed water side and by such arrangement the feed water after feed pump
enters the hp heater. the steam supply to these heater from the bleed point of
the turbine through motor operated valves.

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Condensate water cycle: - It deals with the water flowing through the
condenser which plays an important role in increasing the efficiency of the
plant. It consists of a feedback path from main ejector to hot well.

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
de-aerator through ejectors, gland steam cooler and series of LP heaters
Condensate pump: the function of these pumps is to pump out the
condensate to the deaerator taken to the de-aerator through ejectors, gland
steam cooler and series of LP heaters. This pump is rated generally for 160
cubic meter/hour at a pressure of 13.2 kg/cm square.

LP heater: - there are four LP heaters in which 4 extractions are used.

These heaters are equipped with necessary safety valves in the steam space
level indicator. The condensate flows in the u tube in 4 passes and extraction
steam washes the outside tubes.

Deaerator: - the inner corrosion can be prevented by removing dissolved

gases from the feed water. it can be achieved by embodying into the boiler

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feed system a deaerating unit whose function is to remove the dissolved

gases. it works on two principles:: Henry law and solubility law.
Solubility law: solubility of gases decreases with increase in pressure and /or
decrease in pressure.
Henry law: the mass of gas with definite mass of liquid will dissolve at the
given temperature and is directly proportional to the partial pressure of the
gas in contact to liquid.

Primary air cycle: - In this cycle, air is used to carry pulverized coal
from mill to the burning zone of boiler. Two P.A fans in a thermal power
plant to produce air of required quality( pressure around 700mm of water
column) to elevate the powdered coal from the pulveriser to the burner. For
supplying coal 2 each & every elevation one pulveriser is there & the temp.
of mixture of coal and air is controlled by mixing hot(throughAir Pre
Heater) and cold primary air at the inlet of pulveriser.

Secondary Air cycle: - In this cycle, fuel is mixed with air (known as
secondary air) for proper burning of coal .Secondary air is made available
from forced draft fans.
F.D fans take suction from the atmosphere and discharge through the wind
box arranged to both left & right of the boiler .First wind box is at the
corner 1&2 and the other at the corner 3&4.The required quantity of
Secondary air into the furnace from the wind box is measured in terms of
oxygen in the flue gas is controlled by a no. of secondary air dampers
placed b/w wind box & furnace.(4 nos. for each elevation).

Flue gas cycle: - In this cycle, gas containing waste materials are
removed from the system using various techniques like electrostatic
precipitator, ID fans etc. The flue gas, before being removed is used to heat
the primary and secondary air.
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IMPORTANT EQUIPMENTS OF PLANT

I. Mechanical Equipments:-

a.)Steam generating unit:-

Each steam is of semi outdoor, natural circulation, balanced draft type
designed to burn coal in pulverized form. It is direct fired type meeting the
requirements of latest Indian Boiler Regulation. It has a boiler rating of
375/380 tonnes per hour of steam at a super-heater outlet, at a steam
condition of 139kg/cm2 and a temperature of 5400C.

A re-heater is provided for reheating the exhaust steam from high pressure
system of the turbine to 5400C. The boiler furnace and the gas passages are
designed for low pressure in order to minimize the corrosion & slugging
effect. Closed pitched bore wall tubes with membrane/skin type construction
is adopted for the steam generator furnace walls to ensure maximum
availability and efficiency at MCR not less than 86%.

The unit is provided with two forced draft and two induced draft fans driven
by constant speed electric motors. Each fan is rated for 60% of MCR rating.
Regulation of draft system is by inlet vane control for Forced Draft fan. Shut
off dampers is equipped with pulverized coal firing air fans, coal air pipes,
burners, etc. Four – five pulverized mills are provided for each steam
generator out of which 3 – 4 are capable of meeting MCR with design coal.
Flame scanner is also provided. Furnace Surface Safeguard Supervisor
(FSSS) system is also provided to reduce the risk of explosions and back
fires in the steam generators.

For flame stabilization as well as operation at lower loads, oil burners are
provided. Light oil/gas pilot torch system is adopted for ignition of furnace
oil and pulverized coal.

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b.) Mechanical Dust Collector & Electrostatic

Precipitators:-

Combined – mechanical dust collector & electrostatic precipitator are

provided to arrange arresting of fly ash in order to reduce particle. Efficiency
of about 98% is achieved in this combined system.

c.) Turbine Generator Unit:-

A standard multi-stage, tandem compound extraction type, reheat type,

condensing turbine with seven uncontrolled extractions, operating at
3000rpm is designed to operate with steam condition of 130kg/cm2 at 5350C
at the throttle with reheating at an intermediate stage of 5350C and the
exhaust against a condenser pressure of 0.092kg/cm2 absolute is provided
and is directly coupled to a hydrogen cooled horizontal shaft, totally
enclosed rotating field type generator, designed to generate at 11,000kV,
50Hz, 3-phase with suitable high frequency excitation system. The turbine
and the generator have a nominal rating of 1, 10, 000kW and 1, 25,000kVA
respectively at 2kg/cm2 H2 (gauge) pressure.

The turbine is provided with hydraulic (oil) governing system. The turbo-
generator is complete with all auxiliary systems and equipments, lubrication
systems, shaft, gland seal system, motor operated turning gear. All necessary
protective and supervisory instruments are provided to ensure trouble free,
safe and efficient operations of the units. The turbine – generator is
manufacturebyBHEL

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d.) Condensing Equipments:-

Turn surface condenser of identical design, capable of maintaining a vacuum

of about 0.92kg/cm2 while condensing the steam at maximum rating of the
turbine is provided. These tubes are of aluminium–brass and tube sheet is of
aluminium-bronze. The condensers are spring mounted and directly
connected to the exhaust flange of the turbine with its axis to the right angles
to that of the turbine.
One starting ejector and two 100%
capacity running ejectors are provided to create and maintain the vacuum in
the condenser by taking out air and other non-condensable gases.

e.) De-aerating heater & Closed heaters:-

The unit is provided with a de-aerating heater and proper capacity of a feed
water tank of approximately 14min storage capacity when machine is
running at full load.
The tray type de-aerator is designed to keep the oxygen content to 0.007ppm
so that the oxygen content in the boiler feed pump water is kept below any
chemical detection.
Steam from extraction line and auxiliary heater is supplied to the de-aerator
which maintains a constant pressure of 6kg/cm2 abs. and the boiler feed
pump at the constant pressure irrespective on the load on the turbo-generator.
The feed tank of de-aerator heater is placed on a suitable elevation to provide
sufficient NPSH for the boiler pumps. Level controllers & communication
through level switches is provided to keep the level of the condensate in the
storage tank at a preset value.
Regenerative in the storage on the condensate is carried out in seven stages
by steam of non-regulated extraction from the turbine and tapping from cold
reheat lines. The high pressure cold heaters are both drain cooling and de-
superheating zones in addition to normal condensing zones. The low
pressure feed water heaters are equipped with only drain cooling and
condensing zones.

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f.) Boiler :-

• A steam generator is complex integration of following accessories:

1. Economizer 7. Div panels
2. Boiler drums 8. Platen SH
3. Down comers 9. Re-heater
4. CCW pumps 10. Burners
5. Bottom ring header 11. APHs
6. Water walls

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Economizer:-

• Boiler Economizer is feed-water heaters in which the heat from waste

gases is recovered to raise the temperature of feed-water supplied to the
boiler.
• It preheats the feed water by utilizing the residual heat of the flue gas.
• It reduces the exhaust gas temperature and saves the fuel.

Boiler drum:-
• It is an enclosed Pressure Vessel
• Heat generated by Combustion of Fuel is transferred to water to
become steam

• Serves two main functions.

• Separating heat from the mixture of water and steam.

• It consists of all equipments used for purification of the steam after

beingseparated from water.
Boiler drum level control:-

• Important for both plant protection and equipment safety.

• Maintain drum up to level at boiler start-up and maintain the level at

constant steam load.

• Decrease in this level will uncover boiler tubes and get overheated and
damaged.

• Increase in this level will make separation between steam and

moisture difficult within drum.
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• Controlled circulation is required to maintain the difference in the

density between water and steam with increase in pressure.

Down comers:-

• It carries water from boiler drum to the ring header.

• They are installed from outside the furnace to keep density difference
for natural circulation of water & steam.
• Heating and evaporating the feed water supplied to the boiler from the
economizer.
Water wall:-
• These are membrane walls, no. of tubes are joined.
• Vertical tubes connected at the top and bottom of the Headers.
• Receives water from the boiler drum by down –comers.

Advantage:-
• Increase in efficiency
• Better load response simpler combustion control.
• Quicker starting and stopping
• Increased availability of boiler.
• Heat transfer is better
• Weight is saved in refractory and structure
• Erection is made easy and quick
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g.) HP & LP Bypass System:-

Provision of HP & LP bypass system is proposed having a capacity of 40%
steam bypass, making the unit suitable for quick restart as well as peaking
purposes. This has been necessary on account of grid conditions which
shows very acute storage of peaking.

Auxiliary systems:

The following auxiliary systems for the 4X110 MW as envisaged is

described below:-
a.) Coal Handling System:-

Railway is only the means of transport of coal to this power station. Annual
coal requirement for 4X110 MW units is estimated to be approximately
13.70 lakhs mega tonnes. The coal yard in the layout is adequate for about
30 days storage with two coal stock piles and considering 3800 MT of coal
requirement daily.
Considering inadequate & irregular coal movement by railways it is
adequate to have a marshalling yard capable of handling two rakes a day
normally & three rakes occasionally. Railway siding and marshalling yard is
capable of meeting this requirement.
The coal handling system consists of two wagon tipplers with integral
weight bridge and marshalling equipment for unloading coal into hoppers.
Duplicate belt conveyor system each rated 600 tons/hr feeds coal from the
tippler hoppers to Crusher House. There are two crushers, each rated
600tons/hr. Crushed coal is either stacked in crusher coal yard or conveyed
straight to power house. Duplicate conveyor system carries coal to the top of
boiler bunkers. To stackers/re-claimers are there for stacking and re-claiming
of coal each rated 600 tons/hr.
In the power house, over the bunkers, duplicate belt conveyors run, each
provided with a travelling tippler. Suitable arrangements are made for
magnetic separation of iron particles from coal at the inlet to the crusher
house. An automatic belt weighing system is provided at the power house
entry point to register the amount of coal fed into the bunkers. For
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emergency, manual arrangements are made for unloading the coal from
wagons and conveying the same to the crusher house.
Necessary dust suppressing equipment and ventilation equipment is provided
as a part of the coal conveying system. The operation of the entire system is
controlled and supervised from control room. The system also has necessary
interlock & safety features. For the purpose of shunting, it has three diesel
locomotives.

b.) Fuel Oil System:-

The fuel oil is made available to the power station in tank wagon. The lighter
grade oil such as light diesel oil is made available for starting of boiler from
cold condition & furnace oil is made available for flame stabilisation
purpose during low load operation and during any other period when flame
stability is not satisfactory. The oil received from the tank wagon is pumped
into the storage tank. The railway siding facilities provided is able to
accommodate on the rake of tank wagons. Two storage tanks for heavy oil
and one for light oil is provided. Provision is made for heating the tanks,
steam tracing the piping and supply of heating steam to tank wagons.

Oil from storage tank is pumped into day oil tanks. The day oil tank is
located near the boiler. Pumps and heaters sets of suitable design then pump
the oil from day storage to the burner. Return oil is fed back into the day
tank. Similar installation is provided for the light oil but the day tank is not
present.

c.) Ash Handling System:-

The ash disposal area is within the distance of 4~5kms from the power
station and this is a low lying area. The ash from the boiler hoppers is
conveyed to the ash disposal area either by direct sluicing or hydro-
pneumatic system. Boilers manufactured by M/s. BHEL or AVB are so
designed that it was possible to adopt either of the system for both fly as well
as bottom ash.
The ash disposal area has adequate capacity for storage of ash for a 640
MW station for over 15 yrs without reclamation. This area is now being used
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by Jaypee cement factory for production of cement and ash bricks. However
this area may also be used for agriculture purposes by covering it with a
layer of silt brought from the raw water reservoir in future.

d.) Cooling Water Management:-

The general arrangement & the system have been discussed earlier in
the report. Only the equipments involved in the mechanical system are
described below:-

Water from the raw water reservoir is pumped through clarifloculators.

The clarified water from these clarifloqulator flows to the cooling water
basin by gravity. A clarified pump is present which pumps the clarified
water to the DM plant. For this, three pumps are involved. The outlets
from the cooling water tower basins are connected to the common
tunnel which takes the water back to the power house. From this tunnel
water is drawn through the following pumps to the various equipments
as follows:-

1) CW Pumps for circulating cooling water through turbine,

condenser and discharging the same to the op of the respective
cooling towers. Two CW Pumps each rated 50% capacityis
installed.
2) Auxiliary Cooling Water Pumps for supplying cooling water to
various auxiliary equipment for their cooling. This water after
circulation through various bearings and heat exchangers leadsto
the CW discharge pipe from the condenser for cooling through the
cooling tower. The number of pumps in this case is also two, each of
50% capacity.
1. 3) Ash Water Pumps for supplying water for ash handling.There are
two pumps per unit. Ash water is discharged to the ash disposal area
but this continues the part of cooling water blow-down as well and
therefore forms the part of total make-up water of the cooling tower.

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e.) Water Treatment Plant:-

A demineralising plant is provided for supplying make-up water for the
heat cycle. Clarified water is pumped from the clarified water storage pit
which passes through pressure filter, activated carbon filter, cation
exchanger, degasifier, anion exchanger and mixed bed exchanger. There
are four streams each rated 30m3/hr. Adequate facilities are provided
for unloading, handling and storage of chemicals. Waste effluent is
neutralised before it is discharged to outside drain.

CONTROL AND INTRUMENTATION UNIT

With the increasing size of modern plant, the distance between items of
plants and centralised control room. Also, with large no of instruments, it
becomes very difficult to watch many instruments and supervise the
operation of such a large no of equipment.

A control unit relives the operator from routine tasks, leaving him free to
concentrate on the over all inspections. Also it is very difficulty the
operation engineer to keep to keep constant watch on these temperature
gradients, but it’s become very easy by using control units.

The conventional central control unit is rather a cumbersome system. Large

no of instruments must be observed to know what is happening in side the
plant. The job is simplified by collecting all measurements transmitted from
the process, converting them into digital form and printing them on to log
sheets. All the important measurements at one time are printed along arrow.

The major variables to be controlled are:-

• Super heater & re-heater outlet temperature at a preset value

• Feed water flow to the steam generator
• Mill temperature
• Combustion control by controlling fuel air Condensate recirculationfrom
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condensate discharge line to the condenser

• Level control of heaters, condensers & clearator feed tan
• Boiler feed pump recirculation control

DISTRIBUTED CONTROL SYSTEM

EXPLANATION
➢ It is a closed loop or feedback system.

➢ System is set to fixed value known as SET POINT.

➢ Deviation of the measured value from set value describes the

controlling action to be performed.
➢ Control value to be sensed by sensor and the deviation from SET Pt. is
measured and a Error signal is generated

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DDCMIS–TECHNOLOGICAL BACKGROUND
(Distributed Digital Control, Monitoring Information System)

• PROGRESS OF INSTRUMENTATION USED TO IMPLEMENT

AUTOMATIC PROCESS CONTROL
• LOCAL PNEUMATIC CONTROLLERS
• MINIATURIZED AND CENTRALIZED PNEUMATIC
CONTROLLERS AT CONTROL PANELS AND CONSOLES
• SOLID-STATE CONTROLLERS

• COMPUTERISED CONTROLS (SUPERVISORY)

• DIRECT DIGITAL CONTROL(DDC)

• DISTRIBUTED MICROPROCESSOR BASED CONTROL

Disadvantages of earlier Systems

• Analog instrument panels required huge space, lot of wiring and are
less user friendly for monitoring of large number of parameters.
• Accuracy obtained with solid-state controls is not good and they tend
to drift with time.
• Supervisory controls are inflexible as changing of control
configuration requires change in routing of wires.
• Use of centralized control leads to complete failure.

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MAN-MACHINE INTERFACE AND PLANT INFORMATION

SYSTEM

• 64-BIT SERVER/OWS WITH HIGH-SPEED AND LARGE

MEMORY (256/512 MB RAM, 8 GB HDD FOR SERVER AND
128/256 MB RAM AND 4/6 GB HDD FOR OWS) TO ENSURE
FAST RESPONSE

• PROVISION OF LVS
• CONNECTION TO OTHER SYSTEM THROUGH
STATIONWIDE WAN
• TRANSPARENCY NO 9 & 10
MMIPIS FUNCTIONALITIES
• VPC OPERATION
• OTHER OPERATOR INFORMATIONS THROUGH
VARIOUS DISPLAYS
• ALARMS, LOGS, HISTORICAL AND LONG TERM
STORAGE.
• PERFORMANCE AND OTHER CALCULATIONS

BRIEF INTRODUCTION OF maxDNA

Bharat Heavy Electricals limited (BHEL), Electronics Division, has

entered into a Technical Collaboration Agreement (TCA) for the
manufacture and supply of new generation Distributed Control
Systems 'MAX1000+PLUS' , for modern Power Plants & Industries,
with MAX Control Systems (MCS) Inc USA, part of METSO
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Automation.
The MAX1000+PLUS is now re-named as maxDNA. Where-in
DNA stands for Dynamic Network of Applications. maxDNA is a
network of applications where diverse hardware and software
solutions co-operate to allow the plant to reach its greatest potential.
BHEL's Electronics Division has established itself in the area of
Control & Instrumentation for new power plants as well as
renovation and modernization of existing power plants. A leader in
the Indian Power Sector market, it has already supplied and
commissioned above 200 sets of DCS for thermal, combined cycle
and hydro sets all over the country and overseas.
MCS Inc., USA, former systems division of Leeds and Northrop,
USA, is an internationally reputed technology leader In both Power
as well as Industrial process control systems, with 70 years of rich
experience in the field.

Applications
maxDNA systems are used in many applications throughout the
world including electric power generation, co-generation, cement,
glass, ceramics, primary metals, chemicals and petroleum, water and
waste-water treatment and incineration plants.

BHEL offers a variety of solutions for Power Plants ranging from

simple control systems to complex unified automation for Power
Plants of any size. The synergy of BHEL's expertise in Power Plant
Controls and cutting-edge technology of maxDNA provides for
unified DCS solution for entire Power Plant comprising of Steam
Generator, Steam Turbine Generator and Balance of Plant C&I. The
state-of-the art control system is also configured for complete range
of Hydro Turbine governing and auto sequence controls,
SCADA systems and for wide range of industrial process
application
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The spectrum of applications in brief are as listed.

Power Plant Controls

o Steam Generator Controls

o Heat Recovery Steam Generator (HRSG) controls
o Steam Turbine controls
o Industrial Steam Turbine Controls
o Balance of plant controls
o Data Acquisition and information management
o Hydro Turbine Governing and Auto sequence controls
o Generator and Switchyard controls
o Electrical System controls
o Fossil power utility plants
o Combined cycle power plants
o Captive power plants

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Furnace Safeguard Supervisory System(FSSS)

FSSS (Furnace Safeguard & Supervisory System) is used in almost all types of
boilers to ensure safe operation. The system has been designed to offer maximum
protection, minimum nuisance trips, minimum power consumption and maximum life
of the components used. It is to ensure the execution of the safe, orderly operating
sequence in the start-up and shutdown of fuel firing equipments in a boiler and to
prevent errors which may be committed by an operator due to ignorance. The system is
complex one and has got multiple steps which cannot be left at the discretion of
operators to follow it in a sequential manner. The system is designed in such a manner
that it eliminates the possibility of the unburnt fuel accumulated inside the furnace that
may lead to explosion on sudden ignition.

The BMS (Burner Management System) or FSSS system shall be designed to

perform the following functions-
• Prevent firing unless a satisfactory furnace condition obtained (furnace
purge completed).

• Prohibit start-up of the equipment unless certain permissive interlocks have

been completed.

• Monitor and control the correct component sequencing (manual or

automatic) during start-up and shutdown of the equipment.

• Conditionally allow the continued operation of the equipment only while

certain safety interlocks remaining satisfied.

• Provide component condition feedback to the operator and, if so equipped,

to the plant control systems.

• Provide automatic supervision when the equipment is in service and

provide means to cut out the fuel supply to the furnace in case of unacceptable
firing conditions.

• Cut out fuel (MFT) upon certain adverse unit operating conditions.

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Turbine Supervisory Instrumentation(T.S.I)

Some important are measured for supervision of the turbine are as

follows:-

1. Turbine speed
2. Shaft eccentricity
3. Bearing vibrations
4. Differential expansions
5. Overall expansions
6. Axial shift.

FUTURE PROSPECTS OF NTPC TANDA

NTPC Tanda is providing electricity to 3 different cities (Gorakhpur, Basti &

Sultanpur).At present time, plant is delivering electricity up to PLF 102% i.e.
generating power more than specified. In near future, generating capacity of
plant is going to be increased by two units of 660MW each. So NTPC is
playing a major role in development of INDIA.

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Upendra Kumar Singh