A

TRAINIG REPORT
ON
Guru Hargobind Thermal Power Plant
LehraMohabbat
(Bathinda)

PUNJAB TECHNICAL UNIVERSITY, JALANDHAR

Submitted to- Submitted by- Naveen

Semester -4th
Branch
-Mechanical Roll no
- 1413147

GURU RAM DAS INSTITUTE OF ENGINEERING

AND TECHNOLOGY
LEHRA BEGHA

1
 PROFILE OF THE PLANT

OWNER BOARD Punjab State Electricity

Board

NAME OF THE PLANT Guru Gobind Singh Thermal Plant

SITE LOCATION between 129 Km and 132 Km,

Milestone on Bathinda-Barnala
Road

MAIN COMPANIES TATA HONFY WELL and

EVOLVED BHEL

CONSTRUCTION IN 1992
STARTED

COMMENCE MENT IN DECEMBER 1997

OF 1ST UNIT

COMMENCE MENT IN AUGUST, 1998

OF 2ND UNIT

COMMENCE MENT IN JANUARY, 2007

OF 3RD UNIT

TOTAL SET UP COST 1200 Crores

2
TOTL CAPACITY OF 920 MW
THE PLANT

TOTAL UNITS IN 4
THE PLANT

GNERATION COST 112 Paisa/kW

OVERALL EFFICIENCY 95%

OF THE PLANT

HEIGHT OF CHIMNEY 220 Meters Multi Flue

SOURCE OF WATER Bathinda Branch of

Sirhind Canal

3
 CHAPTER-1
BRIEF HISTORY OF PLANT

Ever widening gap between the power demand and its availability in the
state of Punjab was one of the basic reasons for envisaging the thermal plant
at “Lehra Mohabbat” Distt. Bathinda. The other factors favoring the
installation of this thermal were low initial cost and less generation period as
compared to hydroelectric generating stations, its good railway connection
for fast proximity to load center. Guru Gobind Singh thermal plant is
Government undertaking (under P.S.E.B.).
Initially it was going to set up at Bathinda under GNDTP but the air
force personal restricted its set up at Bathinda hence plant site is shifted to
Lehra Mohabbat about 22Km from Bathinda city. Later this plant was
approved as a separate autonomous body its name as Guru Hargobind
Thermal Plant.
The construction of the plant commenced in 1992 and its unit
started working in December 1997. Its second unit commenced in August
1998. The main companies whose technology pawed the way of this plant
are TATA Honeywell & BHEL in turbine and boiler control .The total set up
cost of the plant is 1200 crores and the capacity of the plant is 2 *210+2*250
=920 MW. The over all efficiency of the plant is 95%. The power
availability from the plant now meets 20-25% of the total power requirement
in Punjab. It has gone a long way in ushering prosperity in the state by
emerging a large number of agricultural pumping sets, more industrial
connections, 100% rural electrification, increased employment potential
reliability and improvement in continuity of supply and system and removal

4
of power cuts to a great extent. It has also led fast development of
environment in area around District Bathinda by providing employment to
about 3000 persons. Two new units of 250MW each are started,
1.1 The following considerations have to be examined in detail before
selection of site for a plant: -
A Availability of fuel such as coal.
B Ash disposal facilities.
C Space requirements.
D Nature of land.
E Most important availability of water.
F Availability of labour.
G Transport facilities.
H Public Society problems such as pollution.
I Development of backward area.

5
 CHAPTER-2
RAW MATERIAL AND THEIR SOURCES

2.1 INTRODUCTION

Power generation is using coal, HFS etc. as burning fuels for

the generation of steam from demineralised water.
Coal coming from West Bengal & Bihar via Rail wagons of
3800 Kcal/kg & 35% ash contents as the minimum requirement with rate of
rupees 680/-p.tone. &4000 Tons per Day in quantity.
Water is taken from Sirhand canal by the tunnel link of
underground 2600mm dia pipes, which is collected in water pond of 150
arcs area & capacity 100000 cubic meters.

2.2 POWER DISTRIBUTION

Electric Power Generated here is send to various sectors through

distribution center. This is the main product of the plant, which is our
nation’s wide requirement. Electric Power drives all our factories, industries,
Railways, Domestic equipment etc. Overall our life is dependent on the
electric power now days.
Distribution center distributes power from here to Barnala Sub
Distribution Mansa, Bathinda, Delhi, Ludhiana and Duri as per
requirements.

6
 CHAPTER-3
BASICS OF A THERMAL PLANT

In a thermal plant, heat energy is converted into mechanical energy of

turbine that is further converted into electrical energy with the help of
generator.
The three main processes are: -
Process AD: - Water is admitted to the boiler, raised to boiling
temperature and then superheated.
Process DF: - The super heated steam is fed to the turbine where it
does work on blades and rotates it.
Process FA: - Heat rejected to the condenser. Circulating water
carries a very large proportion (40-60% of total heat).

3.1 PROCESS OF POWER GENERATION

A generating unit of thermal plant consists of boiler unit, a turbine with

accessories, a generator, a unit transformer and other equipment all arranged
to operate as complementary part of a complete monolithic set. The plant
Overview diagram, which shows the process of generation of electricity, is
on the next to next page.

3.2 ELECTRICITY GENERATION PROCESS EXPLANATION

The coal travels by the conveyer belts from the coal

handling plant to the coalbunkers from where it is fed into pulverizing mills;

7
which grind the coal into powder. The powder coal is carried from the mill
by steam of air heated air in the air heater driven by primary air fan (PA) to
boiler burners where it is blown into the furnace and burns like a gas a force
draft fan provide addition controllable to the burners to assist combustion.
The product of this combustion is dust and ash. (Ratio of 5to 1) the ash to
the bottom of the boiler and is periodically sluiced to mash setting pits .The
dust carried in the fuel gas to the precipitators where it is extracted by high
voltage electrodes. The dust is then conveyed to settling lagoons or removed
by the road for safe. The fuel gas passes by an induced draft fan (ID) to the
chimney. The heat released by the burning coal is absorbed by long length of
tubing which forms the boiler valves. Inside the tube extremely pure water
that is known boiler feed water is converted by the heat into steam at high
pressure and temperature. The steam is then superheated in further tubes and
passes to the high pressure (H.P) turbine where it is discharged through the
nozzle into the turbine blades. The energy of the steam striking the blades
make the turbine rotates after passing through the high-pressure turbine. The
steam is returned to the boiler for reheating before passing through the
intermediate pressure turbine (IPT) and to the low-pressure turbine (LP).
Coupled to the turbine shaft is rotor of the generator, a large cylindrical
electromagnet, so that when the turbine rotor rotates, other rotor rotates with
it. The generator rotor is enclosed in the stator; which consist of large coils
copper bar in which electricity is produced by the rotation of magnetic field
created by the rotor. The electricity from the stator winding goes to a
transformer; which increase its voltage so that it can be transmitted over the
power lines into grid system. Mean while, the steam that is exhausted its
useful energy in turning the turbine is turned back into water in the
condenser so that it can be Used again in the boiler.
8
The diagram showing this whole process is shown

COAL PLANT

Conveyer belt

BOILER BUNKERS

PULVERISING MILLS

BOILER BURNER
FD Fan

COMBUSTION
Dust
Ash

CLEARED FUEL GAS PASS TO CHIMNEY

VIA INDUCED DRAUGHT FAN

COAL BURN

Heat released
BOILS WATER WHICH GIVES STEAM

STEAM IS SUPERHEATED

PASSES TO H.P TURBINE

9
 EXHAUSTED STEAM CONDENSER USED AGAIN IN
ENERGY BOILER
Steam
TURBINE BLADES WATER IS PUMPED

CAUSES TURBINE HEATED IN LP HEATERS

TO ROTATE

DEAERATED IN
STEAM IS RETURNED TO
DEAERATOR
BOILER FOR REHEATING

PRESSURE INCREASES
TIRBINE SHAFT IS COMPLED BY BOILER FEED PUMPS
TO ROTOR OF GENERATOR

GENERATOR ROTOR IS HEATED IN HP

ENCLOSED IN STATOR HEATERS

ELECTRICITY IS PRODUCED AT ECONOMIZER

STATORWINDINGFROM WHICH
IT GOES TO TRANSFORMER
STEAM DRUM

POWER IS STEPED UP
BY TRANSFORMER STEAM IS HEATED
IN SUPERHEATER

GRID SYSTEMS
HP TURBINE

FLOW CHART OF PLANT OVERVIEW

3.3 BLOCKS DISCRIPTION

10
3.3.1 SUPERHEATER (SH)
Before entering in the boiler at the economizer the water is pumped by
condense extract pumps heated in the low pressure (L.P.) heaters, deaerated
in the deaerator increased in the pressure by boiler feed pumps and heated
further in high pressure (HP) heaters. The water passes through the
economizer to the steam drum then up through the furnace wall–tubing
before returning to the steam drum for steam separation. The steam leaves
the drum and heated further in the super heater on its way to the HP Turbine.
The condenser contains miles of tubing’s through which the cold water is
constantly pumped.
Super Heater (SH) is a plain tubular, non-drainable vertical in line spaced
type, arranged for parallel flow. This super heater (SH) is located in the
horizontal path after reheater. Next to Super Heater is Reheater System.
3.3.2 REHEATER SYSTEM (RH)
The reheater section is the single stage; spaced type, continuous loop, and
plain tubular, non-drainable, vertical in line spaced type, arranged for
parallel flow.
3.3.3 ECONOMISER SYSTEM (ECON)
The economizer system is a single block unit, is of continuous loop plain
tubular, drainable horizontal, in line arrangement with water flow upwards
and gases flow downwards. The economizer tubes are suspended from
economizer intermediate header, using ladder type supports.
3.3.4 DEAERATOR (DEA)
The deaerator (DEA) is provided to remove dissolved corrosive gases from
feed water that goes to the boiler. It prevents internal corrosion of boiler
tubes. The oxygen is reduced to untraceable limits by mechanical means in
the condense living the deaerator.
11
3.3.5 BOILER FEED PUMP (BFP)
Boiler feed pump (BFP) is very important auxiliary of the powerhouse. It
has to take supply of water from the deaerator, and supply it to boiler drum
against the positive drum pressure.
3.3.6 MILLS
Bowl mills have been installed from pulverizing the raw coal. The coal of
maximum size of 25 mm is received in raw coalbunkers from Coal Handling
Plant. From the bunker, this coal is fed into the mill through Raw Coal
Feeder. Regulating the speed of the Feeder can control the feed of the coal
mill.
3.3.7 CONDENSER (COND)
The condenser (COND) is a box type double pass with divided water box
design that facilitates the operation of one half of the condenser while the
other half is under maintenance. The steam space is of rectangular cross
section to achieve optimum utilization of the enclosed volume for necessary
air-cooling section at the center from where air and non-condensable gases
are drawn out with the help of air evacuation pumps. The circulating water
enters the water boxes from bottom and then travels through several tubes
and leaves the condenser through upper water boxes in two distinct paths.
Next to condenser is condensate extraction pump (CEP).
3.3.8 CONDESATE EXTRACTION PUMP (CEP)
There are two 100% capacity condensate extraction pumps (CEPs) provided
in the system. Normally, one condensate extraction pump runs and other is
kept as stand-by. These pumps are of vertical and centrifugal canister type
with the driving motor. Condensate extraction pumps have five stages.
3.3.9 GLAND STEAM COOLER (GSC)

12
The gland steam cooler is used to condense the steam extracted from turbine
glands and to maintain slight vacuum at the turbine glands to avoid steam
leakage to atmosphere from turbine glands. It is a single pass heat exchanger
with the main condensate entering from one end and leaving from the other
end. Air steam mixture passes over the tubes in zigzag path due to number of
baffles and thus steam is condensed there-by heating the condensate inside
the tubes.
3.3.10 DRAIN COOLER (DRN CLR)
Drain cooler (DRN CLR) is provided to sub cool the drains coming from
Low Pressure (LP) Heater to improve the cycle efficiency by heating up the
condensate flowing through the tube system.
3.3.11 LP HEATERS (LP HTRS)
The LP heaters (LP HTRS) are of the surface cooled type. They are designed
for vertical mounting. These heaters are of tube system withdrawal type;
these are of four-pass design. Condensate flows inside the tubes while steam
flows Outside the tubes. The condensed steam is collected in the bottom of
the shell that is drained out.
3.3.12 H.P. HEATER (HP HTRS)
High Pressure heater is supplied heating steam from extraction 5 taken from
IP casing of turbine. The feed water enters first in this H.P heater and after
getting heated goes to High Pressure (HP) heater 6. The feed water flows
through the tubes from coldest zone to the hot most zones before it leaves
the heater. The steam flows from hot most zones to coldest zone and the
drain normally goes to deaerator.

3.3.13 ROTARY AIR HEATER (RAH)

13
The basic principal of operation of Rotatary Air Heater (RAH) is the same as
the liung storm type except that the elements are stationary and the air hoods
rotate with. In the gas pass at approximately 1 rev./min. The axis of rotation
may be vertical or horizontal but again and for similar reasons the vertical
spindle is preferred. The drive is normally through an electric motor
operating a pinion that meshes with the rack on the outer rim of the hood
assembly.
3.3.14 FORCED DRAFT FANS (FD FAN)
To take air from atmosphere at ambient temp. To supply essentially all the
combustion, air can either be seized to overcome all the boiler losses
(pressurized system) or just put the air in the furnace (balanced draft units).
3.3.15 INDUCED DRAFT FANS (ID FANS)
Used only in balanced draft units to suck the gases out of the furnace and
throw them into the stack. Handles fly ash laden gases at temperature of 125
to 250oC.
3.3.16 ELECTROSTATIC PRECIPETATORS (ESP)
The principles upon which Electrostatic Precipitators operates are that the
dust-laden gases pass into a chamber where the individual particles of dust
are given an electric charge by absorption of free ions from a high voltage
DC ionizing field. There are four different steps in the precipitation viz.,
ionization of gases and charging of dust particles, migration of the particle to
the collector, deposition of charged particles on the collecting surface,
dislodging of particles from the collecting surface.

CHAPTER-4
14
 CYCLES INVOLVED IN POWER GENERATION

4.1 AIR CYCLE

4.1.1 PRIMARY AIR CYCLE
The primary air, generated by PA (primary air) fans, is used to carry the
pulverized coal from the coal mils to the furnace.
The Primary Air (PA) fans are two in number. A header called the
PA fan duct of the air is made and two tapings are made from this header.
One is passed through the AIR PRE-HEATER A and B, which, using the
heat of the outgoing flue gases, heats the air, now called the hot primary air.
This hot primary air is now divide into six parts A to F and then sent to the
six coal mills by making a hot primary air header.
The other tapping of air called the cold primary air is also made
into a cold primary header and then divided into six parts A to F to be sent
into six mills.
Now lets consider the action of primary air on the mills by
considering, say, mill A. Hot primary air A and cold primary air A pass
through respective valves in their pipes before entering the coal mill. The
valve is installed as the inlet flow temperature is to be maintained at >175ºC
and the flow of the air flowing in the mill is to be at 54-tons/hr.the outlet
temperature is to be maintained at >65ºC &< 10ºC.
From the mill, four feed outlet are taken, carrying the coal to
furnace. As these are six mills, so there are 24 feeds to furnace.

The feed from each mill enters the furnace at 4 different

corners but at the same elevation or height. The feed from other mills also
enters the furnace at corners but at different elevations.
15
 All the feeds from the mill open equally. Now consider only
one corner of the furnace. The feed from mill A enters the corner of the
lowest elevation and those from mill F at highest elevation. The other feed is
between them. In between feeds A & B, C& D, E & F, there are oil guns
called feed AB, CD, and EF respectively. Below A and above F, There are
auxiliary air inlets in the furnace. The primary air cycle is shown on the next
to next page.
4.1.2 SECONDARY AIR CYCLE
The forced draft fans are used to generate the secondary air,
which is used to help in the ignition and burning of the coal in the furnace. A
common header is made of the two FD fans (A&B) and this passed through
the two air pre-heaters, which heat the air using the heat from the flue gases,
so that the cold air doesn’t bring down the temperature of the furnace. The
secondary air for combustion is preheated up to 317oC by means of
regenerative air-heaters (Rotary Air Heaters). The air heater air out ducts are
interconnected to provide a balanced air flow to the furnace and to make it
possible to operate the unit at reduced load if one fan is out of service.
Distribution of secondary air to Wind Box compartments is
controlled by the secondary air dampers. The steam coil air pre-heaters
(SCAPH) one each at the outlet of FD Fans & before RAH has been
provided to avoid the corrosion of RAH by increasing the temperature of
secondary air entering the RAH when the boiler is initially lighted up. The
secondary air path is shown in fig. That is on the next page.
PA RAH MILLS
FAN A&B A-F
A&B
Air I/l

FURNAC
E 16
FD SCAPH RAH
FAN A&B A&B
A&B
 PRIMARY AIR CYCLE

Air I/l
SECONDARY AIR CYCLE

4.2 FLUE GAS CYCLE

Flue gases travel upward in the furnace and downward through the rear gas
pass to the economizer and air heaters. In the economizer, the some heat of
flue gases is utilized to heat the feed water before it goes to drum. Further in
the air heaters, the residual heat of the flue gases is utilized to pre-heat the
secondary and primary air. From the air heaters, the gases pass through the
electrostatic precipitators (ESP) and induced draft fans to the stack.
Interconnections of the gas ducts at inlet and outlet of electrostatic
precipitators are provided.

RAH ID FAN
FURNACE A&B ESP A, B, C

CHIMNEY
OR
FLUE GAS CYCLE
STACK
4.3 WATER CYCLE

17
 The steam after working in three casings of the turbine i.e.
HP, IP & LP casings is condensed in the surface condenser installed just
below the LP exhaust hood. The condensate is collected in the bottom
portion called ho well from where it is pumped into the Deaerator by
condensate extraction pump (CEP) through different heating stages through
which condensate flows and get heated up gradually before finally reaching
the Deaerator. The various heating stages are Gland Steam Cooler, Drain
Cooler, and LP Heater (1, 2, 3) Deaerator. The approximate temperature rise
of condensate after passing through above heating stages is from 40/45 at
hot well to 166oC at the Deaerator (at full load).
The condensate coming from LP heaters passes the tubes of
vent condenser. The steam transfers its heat to condensate flowing within the
tubes and gets condensed. The non-condensable gases along with some
steam go out of the equipment. The drain (condensed steam) is returned to
the deaerating header.
The condensate after leaving the deaerating header enters
the feed storage tank. From feed water tank, the boiler feed pumps takes
suction of feed water thorough booster Pumps and discharge is fed to the
boiler drum after passing through different heating stages viz. HP heaters (5,
6) and feed water regulation station (FW REG STN).

FM DM
M/U

18
COND. CEP GSC DRN
A&B CLR
 steam

FW HP BFP DEA
REG STN HTRS 5,6 A, B, C

FURNA
CE

MAIN WATER CYCLE

4.4 STEAM CYCLE

Steam is that part of the whole process cycle in which the fluent is
steam i.e. part of the cycle containing steam. Steam is first of all generated in
the boiler with the help of coal as a principal fuel. If it is not present in the
adequate amount or not of high purity then heavy furnace oil (HFO) and
light diesel oil (LDO) is used to produce heat in the furnace.
The heat energy supplied in the furnace is absorbed by the water
walls and gets heated up. This gives rise to the formation of steam bubbles in
the water walls and the risers. The cold water in the drum there continuously
displaces the moisture of steam bubbles and water by destabilizing a natured
circulation. With the help of super heater (SH) the steam is super heated and
passes to the HP Turbine. For high efficiency, the turbine is divided into
19
three stages viz. HP Turbine, IP Turbine and LP Turbine. Now at the starting
the temperature of the shaft of the turbine is less and at once increase in
temperature may cause ‘Sag’ in it therefore few cycles of heated steam
passes through the HP BP so that the conductor in the turbine may achieve
the equivalent temperature of the steam by this there will be no loss of heat
due to temperature difference. Through HP BP it again passes through the
furnace and there it reheats with the help of Repeater (RH) and then it passes
to the IP Turbine at a temperature of about 551 oC . From here it passes
through the LP Turbine that rotates the coils of the generator and electricity
has been produced. Like HP BP, LP BP is present as a direct passage of heat
from IP Turbine to condenser where this steam is again changed into water.

HPT
FURNACE
HP BP
ECON SH

RH
IPT

COND LP BP LPT

MAIN STEAM CYCLE GENE

RATO
CHAPTER-5
WORKING OF THERMAL POWER PLANT AT G.H.T.P.
R
20
 Coal received from collieries in the rail wagons is
mechanically unloaded by wagon tippler and carried by belt conveyor
system to crusher house underground. In crusher house the coal is crushed
up to 25mm. This coal is taken by belt conveyer to raw coal bunkers near
coal mill. The coal is then milled to powder form having up to 0.5mm
to1.0mm dia. There is a raw coal chain feeder that regulates quantity of coal
from bunkers to coal mill where coal is pulverized as said above. That
pulverized coal is then pushed to the boiler furnace by pressurized primary
air from corner feeders. This furnace have water tube wall all around
through which water circulates. Water is converted into steam by heat
released by combustion of coal. The oils L.D.O.&H.F.O are used in
combustion of coal forced by forced draught fan. That air is sent in the boiler
furnace after heating in air heater by using the heat of flue gases.
The greatly heated steam and water is sent to boiler
drum, where the water is separated from steam and the dry steam is sent to
the T.G.set, and the water is again sent to reheater and economizer.
The steam having 130km/m 2 to144km/m2 pressure
and 5400 c temperature is sent to H.P turbine. Turbine is made from
Germany which uses high pressure steam and rotates at 3000rpm.The steam
used in H.P.Turbine is lost its heat up to 2400 c so to reheat i.e. to raise again
the temperature and pressure of the steam. The steam is passed through the
reheater and continuously sent to H.P&L.P turbine, made by B.H.E.L.,
rotated on the same shaft with 3000rpm. The steam from LP turbine is taken
out in a vacuum condenser having (-) 0.9kg/cm2 vacuum. Here the steam is
condensed by cold water pipes ciculation.The condensed steam in form of
hot water is put into the hot wall. From where it is again feed into the boiler
drum through the deaerator, LP heaters, HP heaters, BFP, Economiser etc.
21
The condensating water, which is used to condense steam, takes heat from
steam and it becomes hot. That hot water is taken to cooling tower where it
is dropped from 10m heights to cool water by using natural air draught. This
circulation is made by C.W.pumps
And cooling is done up to 100 c.
The products of combustion of furnace charge are flue
gases and ash. About 20%of the ash falls in the bottom ash hopper of the
boiler and is removed mechanically by mixing with water. The remaining
ash carried by flue gases is separated in the Electrostatic Precipitator where
the ash is electro statically evacuated And this dry ash is dumped in the ash
disposal area. The cleaned flue gases are left to the atmosphere through
220m high chimney using I.D.Fan.
The turbines are coupled to the same shaft upon
which the generator is coupled. The Three phase generator produces 3-phase
supply and which is pumped to the power grid system through generator
transformer by stepping up the voltage which is further send for distribution.
The raw water is taken from ‘Sirhind’ Canal to ponds
and after that some amount of water goes to the boiler through D.M. plant
and the remaining water is clarified and used for the cooling purposes.

CHAPTER-6
SYSTEM DESCRIPTION

22
6.1 INTRODUCTION
G.H.T.P.Thermal Power Plant consists of various systems. These are the
following systems: -
 Coal Handling System.
 Fuel oil system
 Ash handling system.
 D.M. Plant.
 Emergency Power supply system.
 Control & Instrumentation system.
 Data Acquisition system.
 Power supply distribution system

6.2 COAL HANDLING SYSTEM

G.H.T.P.Thermal Plant is coal-based power plant. The annual
requirement of coal for 2 units based on specific fuel consumption of 0.60
kg/kwh is 1.381 million tones .The conveying and crushing system will have
the same capacity as that of the unloading system 1000 TPH.The coal comes
in the coal plant in large pieces. The coal is fed to the primary crushers,
which reduces the size of coal pieces from400mm to 150mm size. Then the
coal is sent to the secondary crushers through forward conveyors be crushed
from 150mm to 20mm as required at the mills. Then the coal is sent to mills
through coalbunkers .In mills coal becomes in powder form, which is sent to
the boiler with the help of priamary air fan. The coal is burnt in the boiler.
Boiler includes the pipes carrying water through them. Heat produced from
the combustion of the coal is used to convert water in pipes into steam. This
steam generated is used to run the turbine. When turbine rotates the shaft of
23
generated which is mechanically coupled to the shaft of the turbine get
rotated and so 3 phases electric supply is produced.
6.3 FUEL OIL SYSTEM
Fuel oil is normally used for start up and for flame stabilization
at low load. Initially in the boiler either L.D.O. or H.F.O. is combusted
before the combustion of the crushed coal from the mill.
Light Diesel Oil (L.D.O.) does not require preheating but Heavy
Fuel Oil (H.F.O.) requires preheating because H.F.O. is very much viscous.
L.D.O. or H.F.O. are used initially because this oil has less heat
of combustion then coal. Heat liberated from the combustion of these oils is
used for starting combustion of coal as soon as coal starting combustion
L.D.O. and H.F.O.is stopped and coal is supplied continuously from the fuel
guns in to the boiler.
The H.F.O. is preheated by using the heat of burnt gases, which
is coming from boiler of the 2nd Unit through Chimney.
6.4 ASH HANDLING SYSTEM
When the coal is burnt in the boiler nearly 35% of the ash is
liberated in the addition with another burnt gases. These ash and gases are
coupled out by the reduce draft fan from the boiler E.S.P. is between the
boiler and I.D.Fan. E.S.P. contains charge electrodes that attract the ash
particles and the collect ash this ash is sent for disposal.

6.5 DEMINERALISED PLANT (D.M)

A Demineralised water treatment plant is provided for supplying make up
water to the boiler.
24
 Water as it occurs is never pure as whatever may be the source always
contain impurities .the major impurities of water are: -
 Non-ionic & undissolved
 Ionic &dissolved
 Gaseous
In the DM plant these impurities are removed chemically & Demineralised
water is sent to the boiler.
6.6 EMERGENCY POWER SUPPLY SYSTEM
For the safe shut down of the plant under emergency conditions i.e. in the
case of total power failure diesel generating sets are purposed to be installed
for meeting the power requirements of the essential auxiliaries.
6.7 CONTROL&INSTRUMENTATION
The function of the control & instrumentation system is to add
the operator in achieving the safe and efficient operation of the unit. The
operator is to be provided with the adequate information considered essential
for start up, normal operation, planned shut down and emergency shutdown
of the unit.
Centralized control of the boiler &turbine generator unit from a
centrally located Unit Control Board (UCB) room is envisaged. It would be
possible
To start or to stop all electrically driven unit auxiliaries
&power operated valves and dampers from UCB expect where
recommended, otherwise, by the main equipment suppliers.

6.8 DATA ACQUISITION SYSTEM

In line with the modern practice of centralized
monitoring and control of large capacity power plants Data acquisition
25
system (DAS) shall be provided for monitoring and logging of different
parameters of steam generator, turbine, important temperature points of H.T
& L.T motors, generator & other auxiliaries of the unit.
The system shall monitor, log, the various
parameters at different time e.g. at the time of start up, shut down, normal
run sudden load throw off positions.
The electronic system of DAS shall be of high speed
and equipment with alphanumeric and trend display CRT and alphanumeric
logging printer.

6.9 POWER SUPPLY DISTRIBUTION SYSTEM

Power supply/control supply panels with
adequate no. Of spare feeders shall be provided to meet the requirement of
primary instruments, secondary instruments, controls panels, DAS,
sequential control system protection and interlock system. Suitable
arrangement for automatic changes over from normal supply to stand by
supply and provision of uninterrupted power supply (UPS) to meet the
essential load requirements shall also be provided.

6.10 SOFTWARE

In the previous section we discuss about how the plant is

working now we studied about the software which help to control the whole
plant automatically from a single place .This main software is distributed
control system and this software is operated through TDC3000 which is
made by Honeywell and other is Max PAC station which is made by BHEL

6.11 DISTRIBUTED CONTROL SYSTEM

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 Functionally and physically separate automatic
process controllers, process monitoring and data logging equipment,
connected with each other to share relevant information for optimum plant
control is called DISTRIBUTED CONTROL SYSTEM.
6.11.1 ADVANTAGE AND DISADVANTAGE

Development of (C&I) technology from pneumatic to

electronic equipment was itself a very big change. In electronic C&I
equipment, various functional blocks were used to function under vintner
dependent circuits and control logic. At this stage these functions were
interconnected by signals through multiple cables.
Application of microprocessor and digital
communication technique made it possible to distribute the C&I equipment
distributed geographically and functionally, reducing multiple cable into
single cable. This inters connection of processing function blocks of a
system is termed as a network (N/W)
The signal level and states previously used through
multiple cables are now digital information packets, multiplexed in time,
around the N/w, sent and received by connected functional processors.
Plant wide C&I automation dependent on these N/w’s, emerging as a DCS.
The important benefit of DCS, which is making it
popular is the fact that even failure of processor or a N/w will not result in
failure of other processors or N/w’s of the system respectively.

6.11.2 MAIN BENEFITS OF DCS OVER CONVENTIONAL C&I

EQUIPMENT

27
  Reduction in cabling in control room.
 Physically and functionally separate modules.
 More uniform operations and tighter controls.
 Excellent information management.
 Better integration of plant controls.
 Considerable reduction over maintenance efforts.
Further advancement resulted in release of MAX station in. This now release
of DCS from BHEL contained new Supervisory LOCAL CONTROL
NETWORKK (LCN).

CHAPTER-7
MAX DNA SOFTWARE

28
7.1 Overview of Max station

Max station is hardware platform through which you may view

and manage your process control environment. Max station may be setup as
an operator’s workstation and engineer’s workstation. The same is installed
on either workstation but protective key (doggle) & password are different.
The function being performed by a particular workstation determines its
minimum hardware requirements.

Important conditions to handle Max station

1. Cable entry: - After when we place all the components of the system
then there must be wiring system to connect the system with each
other and with dcs. After selecting a site of the system, cable entry
must be considered. Standard entry to the cabinet is through the
bottom.
2. Power & Grounding:- Max stations are usually supplied with a
power distribution system which requires independent ac lines
(240V/10A) per line. Workstation be powered from two independent
AC lines that provide filtering & surge suppression protection. If the
extension cords are run near the electrical noise then noise could be
picked up. So all equipment should be connected to the AC safety
ground.
3. Ambient environmental condition:- When we place the system there
should be care about the environmental condition. These conditions
are, the room ventilation source should not be connected directly to
the equipment enclosure.

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7.2 DIFFERENT PERIPHERAL CONNECTED TO MAX STATION

 MONITORS: - Monitors are the peripheral device that uses to display

performance of any device in graphical form or in any other form.
There are two types of monitors:-
1. CRT-based monitors
2. LCD-based monitors
Monitors connected to the workstation through 5pin VGA port.
If workstation has DVI connector then use adapter that make the
coupling between VGA & DVI connector. Input connections to some
CRT-based monitor are made through five BNC connector. In RGB
cable, one side is having 5 pin VGA connector and other side has
separate BNC connectors whose colors are different these colors are
(red, green, blue, grey, black) Multiple monitors are connected with
each other through a video card.
 KVM switch {keyboard/video/mouse}:-KVM switch is used to
operate multiple workstations from one keyboard and mouse.
 SPEAKERS: - speakers are connected to a workstation for audio
annunciation of alarms. The sound cards in the workstations provide a
low-level audio signal on the line-out connector. This signal cannot
directly drive passive speakers. It must be connected to an amplified
speaker.

7.2.1 DIFFERENCE BETWEEN CRT AND LCD BASED MONITOR

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 There must be at least 12-inch space be allowed b/w CRT-based
monitors to avoid electromagnetic interference. If the monitors are too
closed to one another, their picture quality may be diminished.
Whereas LCD-based monitors may be positioned closely together as
they don’t generate any electromagnetic interference.
 The technology of CRT-based monitors requires that relatively
fast vertical refresh rate may be used to drive them. Slower refresh
rate may cause some users to see flickers. However LCD-based
monitor operate differently so that they do not cause flicker. They may
be run at much slower refresh rate (60Hz). Monitor run at faster rate
above 72Hz it will damage the monitor.

7.3 CONNECTING STATIONS & DPU TO THE MAXNET

NETWORK
Workstation & max DPUs communication with one another over
Maxnet. To issues maximum availability and fault tolerance, the
network consist of to complete independent Ethernet networks
( A&B ) network consist of electrical and fiber optic cable Ethernet
switches and fiber optic convertor.
 CABLING: - there are two types of cables used in a MAXNET
are metallic & fiber optic cable. Metallic cable is used for
connection inside the cabinet & fiber optic used for large
geographic area to avoid external noise. Data transfer b/w these
wires is 10Mbps to 100Mbps. Metallic wires is used to connect
workstation to Ethernet switch. Fiber optic cable is used to for
pairing b/w fiber optic converter.

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  Ethernet cabling: - To reduce signal losses the metallic
network connections should be made with category better
unshielded twisted pair electrical cable.
 Ethernet switch:-Ethernet switches are used to interconnect all
nodes of the Maxnet network its desired features are:-
Its support remote management to allow user to check and
configure switch setting and to read and reset port statics. The
features can great help each system maintenance procedure and
help diagnose network problem.
 Fiber optic converters:- The 100base-tx to 100base-fx
converter and 10base T to 10base FL converter are used to
provide optical links to the Maxnet backbone or to individual.
When selecting a converter, look for MDI switch features to
accommodate any straight through and cross over cabling
requirements. It is also desirable for the converter to have
ability to explicitly configure their operational speed and
duplex setting.

Model PDP distributed processing unit, which runs under the window
ce.net real time multitasking operating system, is a processing engine
of the MAX dna distributed control System. The DPU performs
primary data acquisition, Control and data processing functions.
DPU also known as MAXDPU-4F is a self contained Microprocessor
based which occupies a single slot is remote processing unit cabinet
using an 8-wide MAX-PAC backplane. It is designed to operate with
user-defined combination of MAX DNA model and to communicate

32
 with other devices such as PLC and remote terminal unit. DPU scan &
process information that use by another device.
Functions performed by DPU
 Comprehensive alarming and calculations.
 Logging of sequence of events data at 1ms.
 Acquisition of trend information.
 Continuous scanning of model IDP.
 Execution of predefined algorithms called function blocks.

7.4 DISTRIBUTED PROCESSING UNIT

DPU consists of printed circuit board containing
control processor and I/O processors and is installed in MAX PAC
chassis.DPU front panel contains LEDS, mode switch, backup
connector, network connector, takeover and reset buttons. An optional
assembly also contains serial port connector for interface to PLC and
BNC connector for interface to an {IRIG-B} time source it is a BNC
connector.
 Control processor: - DPU consists of single printed circuit board
that contains a Pentium class control processor and a dedicated a
microcontroller for scanning I/O. these are sockets on the board
for 64Mbyte of compact flash & 128Mbyte of DRAM.
 Performance:- Multispeed processing system is built into MAX
DPU, which allows object to be executed in three different time
classes from 10msec to 1/2sec up to 8500 function blocks can be
executed in the DPU. By combining function blocks create
libraries of standards. Size of functional block is small as a

33
 atomic block. DPMS keep track the object size and total
execution time for each time class.
 I/O bus interface:- A Motorola 68332, 32 bit I/O processor and
field programmable gate array(FPGA) are used to interface to
both the mode IOP and I/O bus expander module. Maximum
length of model I/O bus is 30ft. The length of the remote I/O link
with fiber optic extenders is up to 2000m.
 Memory :- All information regarding the operation of DPU
stored in DPU memory including (tag name, descriptions, tuning
constants, alarms limits etc). In addition, all graphical
configuration data is stored in the DPU.
 Sequence of events:- Each DPU includes a built in sequence of
events recorder that can monitor up to 512 discrete inputs. These
inputs are scanned 1000 times a second and state changes are
time stamped with 1ms resolution and stored in DPU’s 1000
event buffer.
7.5 WORKING IN MAX SYSTEM
Working in MAX system will include working
with maxVUE runtime, max storian, Max editor

(i) Working in MAX editor Max editor is basically meant for

making new graphics for max system or for editing of present
graphics. It is used to create and maintain graphics the operator
uses to view and control the process. This application is only
executed in Engineer Workstation.

(ii) Max Storian Max storian is an integrated software module that

allow that allow the MAX Control user to collect ,manages and
retrieve historical information about the operation of their process
The storian plug into the software backplane where it acquire real

34
 time information in the form of reports and trends usable by
operators and others within the plant

(a) HISTORIAN Max storian Process history is a highly

efficient and flexible data collector and compression that
acquire user specified information on a periodic basis, checks
for changes between sample periods, and store the samples
value in hard disk. User can archive process history data to
CD-ROM and use the achieved data for trending and reporting
years after the data was collected and achieved.

(b) TRENDING Max storian Trend allow the user to prevent

historical data as a graphical trend as a graphical trend on CRT
The package support the real time trending and historical
trending. User can change trending tags, time span of trends
and resolution of trended data on line.

 Up to twelve values can be trended per CRT screen

 Add or change points of change the range online
 User can create customizes scales and trend borders

(c) REPORTS Max storian report is the report formatting

and generation facility .This element contain easy to use
redefined report layouts such as trend report, summary report,
shift report and trip report

(iii) MAX DPU Tools Max DPU Tools is software utility that allow
you to create a configuration in offline mode. Using Max DPU
tools you can create configuration database file for each DPU and
define function blocks within the configuration representing an
individual DPU’s associated I/O hardware along with the control

35
(a) Updating the configuration Use the MAXDPU Tools to
create a new database .Remember that ,if you are editing an
existing database, It may need to be converted from earlier
versions .Max DPU Tools support mixed versions of the
maxDPU from a single workstation. This allows a site to have
multiple maxDPU versions present in a system. Multiple
versions may exit for several reasons. For instance, new
equipment is added or a complete update to existing equipment
is not desired or must be deferred until a later date.

(b)Updating the configuration with the same version

MaxDPU Tools will automatically update a configuration

created within the same DPU version when you first open it.
The auto update applies the most current database master
containing the latest definitions.

(c) Uploading maxDPU Tools Changes Any online changed

introduced using maxDNA programs, such as the maxVUE
Graphical Configurator or Point Browser, should also be
uploaded before editing the configuration. Conversion and
upload utilities will write over the original dataset.

(d)Uploading /Downloading of the configuration If you are

editing an existing database, use the configuration upload
Utility to incorporate any changes introduced online on other
programs With the help of DPU tools we can upload the
particular configuration from DPU .After doing certain
modification we can again download the configuration in the
same DPU.

Downloading is also of two types

Complete download This includes down loading the whole
configuration in the DPU

36
 Incremental Download This includes downloading of only a
particular group in to the DPU

7.5,1 Using the Reset button

Pressing the reset button will cause the DPU to

stop controlling and go through a reset cycle. This should not be done
casually as it will cause severe disruptions to yours process. I f the reset
button is pressed for less than 2 seconds; the DPU will save the current
configuration database and then reset itself. If the reset button is depressed
for longer than 3 seconds, the DPU will immediately reset (Hard
Reset).During normal operation the DPU will continually save the
configuration database to Compact Flash. For typical database, this will be
done every 5 seconds.

7.5.2 Using the Takeover Button

Pressing the takeover button can force a previously
inactive DPU to go active. This should not be done casually as the manual
forced takeover occurs regardless of the inactive DPU’s ability to control.
This can have severe consequences to your process.

7.5.3 Redundant DPU operation

In the redundant configuration, two DPU’s are connected to form a backup
pair. One DPU is designed as primary unit and other DPU the secondary unit
.The IP address of the secondary DPU is always one number greater than the
address of primary DPU. The primary is always the even address and
secondary address
7.5.4 Automatic Failover

37
Process control is automatically transferred from primary DPU to the
secondary DPU when the primary DPU experience a severe diagnostic alarm
of when communication between the primary and secondary DPU is lost.

7.5.5 Connecting Stations and DPU’s to Max Net Network

Workstation and DPU’s communicate with one another over MAX NET, a
redundant Ethernet network. To ensure maximum availability and fault
tolerance, the network consists of two completely independent Ethernet
networks (identified as network A and network B) It is assumed that network
A is independent of network B. The network A cable should not be mixed
with network B cables. Network A cables must be connected to network A
only.
Ethernet switches are used to connect all nodes of Ethernet

7.5.6 Demanding a blank startup

When a DPU is first placed in service it is advisable to clear my previous

configuration data that may remain in its flash memory. To do this before
applying power to the DPU, set the mode switch to ‘B’ on the DPU.After the
DPU has gone through its startup sequence to set the mode switch back to F
to prevent future Cold startups.

38
39
 INTERCONNECTION OF DPU WITH I/O MODULES

7.5.7 Starting a standalone DPU

1. Remove the compact flash from the DPU and inset it into a
reader/writer attached to the workstation. Use the Workstation utility
DPU4F setup program to initialize the compact flash. This utility will
configure the IP address, Redundancy, Network Speed and version of
software. Reinstall the compact Flash into the DPU
2. Set the front panel mode switch to B to demand a cold startup
3. Insert the DPU into the chassis slot and secure the DPU using two
thumbscrews
4. Insert the network A cable into the top RJ45 connector and network B
cable into second Rj45 connector

40
 5. Wait until the CP LED begins to blink Yellow/Green signifying that
DPU is operational.
6. Return the mode switch to F
7. Use the DPU4F detailed Status Display to verify that the DPU is
operational.
7.5.8 Demanding a blank startup

When a DPU is first placed in service it is advisable

to clear my previous configuration data that may remain in its flash memory.
To do this before applying power to the DPU, set the mode switch to ‘B’ on
the DPU.After the DPU has gone through its startup sequence to set the
mode switch back to F to prevent future Cold startups.
7.5.9 Starting a standalone DPU

8. Remove the compact flash from the DPU and inset it into a
reader/writer attached to the workstation. Use the Workstation utility
DPU4F setup program to initialize the compact flash. This utility will
configure the IP address, Redundancy, Network Speed and version of
software. Reinstall the compact Flash into the DPU
9. Set the front panel mode switch to B to demand a cold startup
10.Insert the DPU into the chassis slot and secure the DPU using two
thumbscrews
11.Insert the network A cable into the top RJ45 connector and network B
cable into second Rj45 connector
12.Wait until the CP LED begins to blink Yellow/Green signifying that
DPU is operational.
13.Return the mode switch to F
14.Use the DPU4F detailed Status Display to verify that the DPU is
operational.

7.5.9 DPU Switch Setting

41
The DPU front panel contains a hexadecimal rotary switch and push buttons
for reset and Takeover. The mode switch is used to determine the operational
mode of the DPU
Setting Description
A Reserved
B If this mode is set during a reboot of the DPU, the DPU will
clear the configuration database from compact flash and go on
line as in mode ‘F’. Once the mode switch is on line the mode
switch should be moved back to the F position so that an
unexpected restart of the DPU will not erase the new database.
C Network Flash mode where DPU uses a fixed IP and MAC
address. Used when DPU needs to be configured for the first
time .The software can be upgraded on the DPU compact Flash
D Debug mode. This is a factory test mode. The DPU application
will not start automatically.
E Network Flash mode used to upgrade software on the compact
flash.
F Normal operating mode. Will use the database stored in flash if
available.

7.5.10 Tracking point icon in Max Station

By clicking this icon will open the tracking point pop up for the point in the
Point select area. The Tracking point pop –up does not automatically close
when you swap to a new display. This allows you to monitor this point while
swapping to the other displays

42
The tag name for the point is shown in the first line of the popup. The
second line shows the value of interest for the point. The third line shows the
value of measure

1 AI: IOP 301: Isolated input

2 AI: IOP 302: 4-20mA input module
3 AI: IOP 305: Voltage input module
4 AI: IOP303: 3-wire RTD module
5 AI: IOP304: Thermo Couple module
6 AO: IOP320: Analog output module
7 DI: IOP330: 24V common input module
8 DO: IOP350: Form A/B relay module

43
 9 BEM: IOP371: Bus Extender module

7.6 Field Instruments

1. RTD (Resistance Temperature Detector):
RTD is basically a temperature detecting equipment which works on fact
that a temperature change will lead to a change in resistance. There are 3
types:
1. 2-wire RTD
2. 3-wire RTD
3. 4-wire RTD
R1=R0+α T
Where
R1= Resistance at a temperature of T°C
R0 = Resistance at a temperature of 0°C
α = Temperature coefficient, 0.4 generally for our equipment
T = Actual Temperature

44
 FIELD WIRING FOR COMMON RTD MODULE

2. THERMOCOUPLE:
It is also a temperature detecting equipment which works on the
principle of Thermo electric effect or Seebeck effect. According to this
principle, when two junctions of two metals are kept at different
temperatures some emf will be induced across these junctions. Mostly nickel
chromium metal junction is being used. One junction is called cold junction
and another is called hot junction.

Cold junction is made inside the CJB with the particular equipment and cold
junction temperature will be measured by an RTD and transmitted to DCS.

45
Special Nickel-Chromium cable, called as compensating cable is used to
connect the thermocouple to the CJB. This unit may require 24 V dc supply
or 240V AC in our plant.

3. PT (Pressure Transmitter):
A pressure transmitter is a device which generates 4-20mA output
based on the pressure applied. Input may be 24Vdc or 110Vac or 230Vac.
We are using 24V dc power supply. There are three types of these based on
its electrical connections.

They are:
1. 2-wire
2. 3-wire
3. 4-wire
It works on the basic fact that variable capacitance can be achieved by
changing the distance between the plates of a parallel plate capacitor.

4. Auma Actuators
 Calibration of Auma actuators feedback (4-20mA) to DCS using the
provided rheostats for zero adjustment and Max adjustment.
 Adjustment of limit switches arrangement.
5 SOV (Solenoid Operated Valve):
These are the types of valves which are operated with help of air. Mainly
3 or4 kg of air is required for the proper operation of the valve.

46
  Operation of valve (manual also), path of the pressurized air.
 Regulating the air pressure.
 Limit switches arrangement adjustment.
 The solenoid used in these types of valves mainly uses 110V AC

6 Pressure Switches and Temperature Switches

Pressure switches are basically used to indicate HIGH or LOW alarms
values .The switches are calibrated in such way that as the required
limit is obtained the limit switch contact changeover will take place.

47