UNDERTAKEN AT
Haridwar
SUBMITTED BY:
Anurag Chand
10607032
Electronics & Instrumentation
TABLE OF CONTENT
1. Introduction
BHEL
Captive Power plants
2. Operation
Operation of Power Plant
4. Industrial Automation
PLCs (Programmable Logic Controllers)
SCADA
Introduction
BHEL is the largest engineering and manufacturing enterprise in India
in the energy-related/infrastructure sector, today. BHEL was
established more than 40 years ago, ushering in the indigenous
Heavy Electrical Equipment industry in India - a dream that has been
more than realized with a well-recognized track record of
performance. The company has been earning profits continuously
since 1971-72 and paying dividends since 1976-77.
Ø Capacity-23.6 MW.
Ø It is coal fired.
Operation
Coal from the coal wagons is unloaded with the help of wagon tipplers in the C.H.P. this
coal is taken to the raw coal bunkers with the help of conveyor belts. Coal is then
transported to bowl mills by coal feeders where it is pulverized and ground in the
powered form.
This crushed coal is taken away to the furnace through coal pipes with the help of hot and
cold mixture P.A fan. This fan takes atmospheric air, a part of which is sent to pre heaters
while a part goes to the mill for temperature control. Atmospheric air from F.D fan in the
air heaters and sent to the furnace as combustion air.
Water from boiler feed pump passes through economizer and reaches the boiler drum .
Water from the drum passes through the down comers and goes to the bottom ring
header. Water from the bottom ring header is divided to all the four sides of the furnace.
Due to heat density difference the water rises up in the water wall tubes. This steam and
water mixture is again taken to the boiler drum where the steam is sent to super heaters
for super heating. The super heaters are located inside the furnace and the steam is super
heated (540 degree Celsius) and finally it goes to the turbine.
Fuel gases from the furnace are extracted from the induced draft fan, which maintains
balance draft in the furnace with F.D fan. These fuel gases heat energy to the various
super heaters and finally through air pre heaters and goes to electrostatic precipitators
where the ash particles are extracted. This ash is mixed with the water to from slurry is
pumped to ash period.
The steam from boiler is conveyed to turbine through the steam pipes and through stop
valve and control valve that automatically regulate the supply of steam to the turbine.
Stop valves and controls valves are located in steam chest and governor driven from main
turbine shaft operates the control valves the amount used.
Steam from controlled valves enter high pressure cylinder of turbines, where it passes
through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the
steam into a second ring of moving blades mounted on the disc secured in the turbine
shaft. The second ring turns the shaft as a result of force of steam. The stationary and
moving blades together.
A Thermal Power Station comprises all of the equipment and a subsystem required to
produce electricity by using a steam generating boiler fired with fossil fuels or befouls to
drive an electrical generator. Some prefer to use the term ENERGY CENTER because
such facilities convert forms of energy, like nuclear energy, gravitational potential energy
or heat energy (derived from the combustion of fuel) into electrical energy. However,
POWER PLANT is the most common term in the united state; While POWER STATION
prevails in many Commonwealth countries and especially in the United Kingdom.
Such power stations are most usually constructed on a very large scale and designed for
continuous operation. Typical diagram of a coal fired thermal power
station
Cooling towers
Cooling Towers are evaporative coolers used for cooling water or other working medium
to near the ambivalent web-bulb air temperature. Cooling tower use evaporation of water
to reject heat from processes such as cooling the circulating water used in oil refineries,
Chemical plants, power plants and building cooling, for example. The tower vary in size
from small roof-top units to very large hyperboloid structures that can be up to 200
meters tall and 100 meters in diameter, or rectangular structure that can be over 40 meters
tall and 80 meters long. Smaller towers are normally factory built, while larger ones are
constructed on site.
The primary use of large , industrial cooling tower system is to remove the heat absorbed
in the circulating cooling water systems used in power plants , petroleum refineries,
petrochemical and chemical plants, natural gas processing plants and other industrial
facilities . The absorbed heat is rejected to the atmosphere by the evaporation of some of
the cooling water in mechanical forced-draft or induced draft towers or in natural draft
hyperbolic shaped cooling towers as seen at most nuclear power plants.
Electrical generator
Energy in the steam after it leaves the boiler is converted into rotational energy as it
passes through the turbine. The turbine normally consists of several stage with each
stages consisting of a stationary blade (or nozzle) and a rotating blade. Stationary blades
convert the potential energy of the steam into kinetic energy into forces, caused by
pressure drop, which results in the rotation of the turbine shaft. The turbine shaft is
connected to a generator, which produces the electrical energy.
Steam-powered pumps
Steam locomotives and the steam engines used on ships and stationary applications such
as power plants also required feed water pumps. In this situation, though, the pump was
often powered using a small steam engine that ran using the steam produced by the
boiler. A means had to be provided, of course, to put the initial charge of water into the
boiler(before steam power was available to operate the steam-powered feed water
pump).the pump was often a positive displacement pump that had steam valves and
cylinders at one end and feed water cylinders at the other end; no crankshaft was
required.
In thermal plants, the primary purpose of surface condenser is to condense the exhaust
steam from a steam turbine to obtain maximum efficiency and also to convert the turbine
exhaust steam into pure water so that it may be reused in the steam generator or boiler as
boiler feed water. By condensing the exhaust steam of a turbine at a pressure below
atmospheric pressure, the steam pressure drop between the inlet and exhaust of the
turbine is increased, which increases the amount heat available for conversion to
mechanical power. Most of the heat liberated due to condensation of the exhaust steam is
carried away by the cooling medium (water or air) used by the surface condenser.
Control valves
Control valves are valves used within industrial plants and elsewhere to control operating
conditions such as temperature,pressure,flow,and liquid Level by fully partially opening
or closing in response to signals received from controllers that compares a “set point” to a
“process variable” whose value is provided by sensors that monitor changes in such
conditions. The opening or closing of control valves is done by means of electrical,
hydraulic or pneumatic systems
Deaerator
A Dearator is a device for air removal and used to remove dissolved gases (an alternate
would be the use of water treatment chemicals) from boiler feed water to make it non-
corrosive. A dearator typically includes a vertical domed deaeration section as the
deaeration boiler feed water tank. A Steam generating boiler requires that the circulating
steam, condensate, and feed water should be devoid of dissolved gases, particularly
corrosive ones and dissolved or suspended solids. The gases will give rise to corrosion of
the metal. The solids will deposit on the heating surfaces giving rise to localized heating
and tube ruptures due to overheating. Under some conditions it may give to stress
corrosion cracking.
Deaerator level and pressure must be controlled by adjusting control valves- the level by
regulating condensate flow and the pressure by regulating steam flow. If operated
properly, most deaerator vendors will guarantee that oxygen in the deaerated water will
not exceed 7 ppb by weight (0.005 cm3/L)
MAIN GENERATOR
1. RTD
2. THERMOCOUPLES
Pressure Transducers
Bellows-Type Detectors
The need for a pressure sensing element that was extremely sensitive to
low pressures and provided power for activating recording and indicating
mechanisms resulted in the development of the metallic bellows pressure
sensing element. The metallic bellows is most accurate when measuring
pressures from 0.5 to 75 psig. However, when used in conjunction with a
heavy range spring, some bellows can be used to measure pressures of
over 1000 psig.
Bourdon tube
Ball Float
The operation of the ball float is simple. The ball floats on top of the
liquid in the tank. If the liquid level changes, the float will follow and
change the position of the pointer attached to the rotating shaft.
Flow meters
Differential Flow Transmitter
Orifice plates
• Flat plates 1/16 to 1/4 in. thick
• Mounted between a pair of flanges
• Installed in a straight run of smooth pipe to avoid disturbance of flow patterns
due to fittings and valves
Venturi tube
• Converging conical inlet, a cylindrical throat, and a diverging recovery cone
• No projections into the fluid, no sharp corners, and no sudden changes in
contour
The electromagnetic flow meter is similar in principle to the generator. The rotor of the
generator is replaced by a pipe placed between the poles of a magnet so that the flow of
the fluid in the pipe is normal to the magnetic field. As the fluid flows through this
magnetic field, an electromotive force is induced in it that will be mutually normal
(perpendicular) to both the magnetic field and the motion of the fluid. This electromotive
force may be measured with the aid of electrodes attached to the pipe and connected to a
galvanometer or an equivalent. For a given magnetic field, the induced voltage will be
proportional to the average velocity of the fluid. However, the fluid should have some
degree of electrical conductivity.
Only single sensor i.e. level sensor is used to control the level
This uses two sensors level and flow sensors. It is better and precise than single
element control.
This uses a single feedback loop which finds out error from the set point
and finds out controller output
Ratio Control
Ratio control is used to ensure that two flows are kept at the same ratio
even if the flows are changing. E.g. Air-Fuel Ratio where the proper
ratio between air and fuel i.e. pulverized coal has to be
maintained.
Controller feed is adjusted according to the ratio of wild feed. The implementation is
shown above.
Automation of Processes
The main purpose of automation is to minimize human intervention to
reduce the errors. Large processes like power plant has large scope for
errors.
Salient features
PLC HARDWARE
Many PLC configurations are available, even from a single vendor. But,
in each of these there are common components and concepts. The most
essential components are:
Power Supply - This can be built into the PLC or be an external unit.
Common voltage levels required by the PLC (with and without the power
supply) are 24Vdc, 120Vac,
220Vac.
Indicator lights - These indicate the status of the PLC including power
on, program running, and a fault. These are essential when diagnosing
problems.
The configuration of the PLC refers to the packaging of the components.
Rack - A rack is often large (up to 18” by 30” by 10”) and can hold
multiple cards.
When necessary, multiple racks can be connected together. These tend to
be the highest cost, but also the most flexible and easy to maintain.
Outputs from PLCs are often relays, but they can also be solid state
electronics such as transistors for DC outputs or Triacs for AC outputs.
Continuous outputs require special output cards with digital to analog
converters.
Inputs come from sensors that translate physical phenomena into
electrical signals. Typical examples of sensors are listed below in
relative order of popularity.
A motor will be controlled by two switches. The Go switch will start the
motor and the Stop switch will stop it. If the Stop switch was used to stop
the motor, the Go switch must be thrown twice to start the motor. When
the motor is active a light should be turned on. The Stop switch will be
wired as normally closed.
SCADA
Features of SCADA