NTPC REPORT

Control and Instrumentation

SUBMITTED BY:-

ACKNOWLEDGEMENT
I would like to convey my deepest thanks to, Mrs. Rachna Singh Bhal, the Senior Manager (HR-EDC) for her valuable advice and support she has given me in writing of this report. I would also like to thank, Mrs.Reena of C&I Department for her guidance under which I completed my training.

Also I am extremely grateful to, Mr. Manmohan Singh, for giving us the wonderful opportunity to be a part of this esteemed organisation. I would like to extend my gratitude to the technical staff of BTPC to help me throughout during my training by giving me the prerequisite knowledge about the plant before visiting it.

PREFACE
This report is an account of the vocational training, which I undertook at NTPC for 60 days. It also contains an account of various departments I visited during my course of training here. The training which I did at NTPC was a great learning experience and has helped me understand my subject as well as the industry better.

CONTENTS
(1) NTPC Evolution of NTPC Installed Capacity Project Profile NTPC Strategies Use of Waste Products - Ash Utilization BADARPUR THERMAL POWER STATION Classification Electricity Generation FUNCTIONING OF THE POWER PLANT Introduction Steam Generator or Boiler Steam Turbine Electric generator CONTROL AND INSTRUMENTATION Manometry lab Protection and interlocks lab Automation lab Electronics lab Water treatment plant Furnaces Safety Supervisory System Lab AUTOMATION AND CONTROL Pressure Monitoring Temperature Monitoring Flow Measurement

(2)

(3)

(4)

(5)

N.T.P.C.
Corporate Vision: A world class integrated power major, powering Indias growth, with increasing global presence Core Values: B-Business Ethics C-Customer Focus O-Organizational & Professional pride M-Mutual Respect and Trust I- Innovation & Speed T-Total quality for Excellence

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

NTPCs core business is engineering, construction and operation of power generating plants. It also provides consultancy in the area of power plant constructions and power generation to companies in India and abroad. As on date the installed capacity of NTPC is 27,904 MW through its 15 coal based (22,895 MW), 7 gas based (3,955 MW) and 4 Joint Venture Projects (1,054 MW).

EVOLUTION OF NTPC
NTPC was set up in 1975 with 100% ownership by the Government of India. In the last 30 years, NTPC has grown into the largest power utility in India.

In 1997, Government of India granted NTPC status of Navratna being one of the nine jewels of India, enhancing the powers to the Board of Directors.

In 2004, NTPC became a listed company with majority Government ownership of 89.5%. NTPC becomes third largest by Market Capitalisation of listed companies

2005 saw the company rechristened as NTPC Limited in line with its changing business portfolio and transform itself from a thermal power utility to an integrated power utility. Today, NTPC is the largest power utility in India, accounting for about 20% of Indias installed capacity.
INSTALLED CAPACITY Projects COAL GAS/LIQ. FUEL TOTAL No. of Projects 15 07 22 Commissioned Capacity (MW) 22,895 3,955 26,850

PROJECT PROFILE
Coal Based Power Stations Commissioned Capacity (MW) 2,000 2,100 2,600 1,600 3,260 2,000 1,340 840 3,000 1,050 460 1,000 440 705 500 22,895

Coal based 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Singrauli Korba Ramagundam Farakka Vindhyachal Rihand Kahalgaon NTCPP Talcher Kaniha Unchahar Talcher Thermal Simhadri Tanda Badarpur Sipat Total (Coal)

State Uttar Pradesh Chattisgarh Andhra Pradesh West Bengal Madhya Pradesh Uttar Pradesh Bihar Uttar Pradesh Orissa Uttar Pradesh Orissa Andhra Pradesh Uttar Pradesh Delhi Chattisgarh

Gas/Liq. Fuel Based Power Stations Commissioned Capacity (MW) 413 652 645 817 648

Gas based 16. 17. 18. 19. 20. Anta Auraiya Kawas Dadri Jhanor-Gandhar

State Rajasthan Uttar Pradesh Gujarat Uttar Pradesh Gujarat

21. Rajiv Gandhi CCPP Kayamkulam 22. Faridabad Total (Gas)

Kerala Haryana

350 430 3,955

NTPC STRATEGIES
Maintain sector leadership position through expansion

Further enhance fuel security

Sustainable Development

STRATEGIE S

Nurturing human resource

Exploit new business opportunities

Technology Initiatives

TECHNOLOGY INITIATIVES

Introduction of steam generators (boilers) of the size of 800 MW Integrated Gasification Combined Cycle (IGCC) Technology

Launch of Energy Technology Centre -A new initiative for development of technologies with focus on fundamental R&D The company sets aside up to 0.5% of the profits for R&D Roadmap developed for adopting Clean Development Mechanism to help get / earn Certified Emission Reduct

CORPORATE SOCIAL RESPONSIBILITY

As a responsible corporate citizen NTPC has taken up number of CSR initiatives. NTPC Foundation formed to address Social issues at national level. NTPC has framed Corporate Social Responsibility Guidelines committing up to 0.5% of net profit annually for Community Welfare Measures on perennial basis. The welfare of project affected persons and the local population around NTPC projects are taken care of through well drawn Rehabilitation and Resettlement policies. The company has also taken up distributed generation for remote rural areas.

NTPC Faridabad has been doing development work in the nearby villages of Mujedi under the guidance of Mrs. Manjula Sengupta with an annual budget of Rs Ten lacs. ENVIRONMENT MANAGEMENT All stations of NTPC are ISO 14001 certified Various groups to care of environmental issues The Environment Management Group Ash Utilisation Division Afforestation Group Centre for Power Efficiency & Environment Protection Group on Clean Development Mechanism NTPC is the second largest owner of trees in the country after the Forest department.

PARTNERING GOVERNMENT IN VARIOUS INITIATIVES Consultant role to modernize and improvise several plants across the country Disseminate technologies to other players in the sector Consultant role Partnership in Excellence Programme for improvement of PLF of 15 Power Stations of SEBs. Rural Electrification work under Rajiv Gandhi Grameen Vidyutikaran Yojana

ECOLOGICAL MONITORING PROGRAMME NTPC has undertaken a comprehensive Ecological Monitoring Programme through Satellite Imagery Studies covering an area of about 25 Km radius around some of its major plants. The studies have been conducted through National Remote Sensing Agency (NRSA), Hyderabad at its power stations at Ramagundam, Farakka, Korba, Vindhyachal, Rihand and Singrauli. These studies have revealed significant environmental gains in the vicinity areas of the project as a result of pursuing sound environment management practices. Some of these important gains which have been noticed are increase in dense forest area, increase in agriculture area, increase in average rainfall, decrease in waste land etc. In general, the studies, as such, have revealed that there is no significant adverse impact on the ecology due to the project activities in any of these stations. Such studies conducted from time to time around a power project have established comprehensive environment status at various post operational stages of the project. USE OF WASTE PRODUCTS & SERVICES -ASH UTILIZATION Ash is the main solid waste which is put into use for various products and services. NTPC has adopted user friendly policy guidelines on ash utilisation. In order to

motivate entrepreneurs to come forward with ash utilisation schemes, NTPC offers several facilities and incentives. These include free issue of all types of ash viz. Dry Fly Ash / Pond Ash / Bottom Ash and infrastructure facilities, wherever feasible. Necessary help and assistance is also offered to facilitate procurement of land, supply of electricity etc from Government Authorities. Necessary techno-managerial assistance is given wherever considered necessary. Besides, NTPC uses only ash based bricks and Fly Ash portland pozzolana cement (FAPPC) in most of its construction activities. Demonstration projects are taken up in areas of Agriculture, Building materials, Mine filling etc. The utilisation of ash and ash based products is progressively increasing as a result of the concrete efforts of these groups.

NTPC INTERNATIONAL CELL Keeping its proactive tradition, NTPC launched a separate International Cell to meet the varied needs of IPPs ( Independent Power Producers) and other International clients who are looking for a world class service in power sector. The Cell is especially tuned to meet the requirements of International clients in terms of quick response, flexible service options and to deliver value for money.

BADARPUR THERMAL POWER STATION

A thermal power station consists of all the equipments and a subsystem required to produce electricity by using a steam generating boiler fired with fossil fuels to drive an electric generator. Some prefer to use the term ENERGY CENTER because such facilities convert form of energy like nuclear energy, gravitational potential energy or heat energy (derived from the combustion of fuel) into electrical energy. At the centre of nearly all power stations is a generator, a rotating machine that converts mechanical energy into electrical energy by creating relative motion between a magnetic field and a conductor. The energy source harnessed to turn the generator varies widely. It depends chiefly on what fuels are easily available and the types of technology that the power company has access to.

In thermal power stations, mechanical power is produced by a heat engine, which transforms thermal energy, often from combustion of a fuel, into rotational energy. Most thermal power stations produce steam, and these are sometimes called steam power stations. About 80%of all electric power is generated by use of steam turbines. Not all thermal energy can be transformed to mechanical power, according to the second law of thermodynamics. Therefore, there is always heat lost to the environment. If this loss is employed as useful heat, for industrial processes or district heating, the power plant is referred to as a cogeneration power plant or CH (combined heat and power) plant. In countries where district heating is common, there are dedicated heat plants called heat only boiler stations. An important class of power stations in the Middle East uses by-product heat for desalination of water. CLASSIFICATION BY FUEL Nuclear power plants use a nuclear reactor's heat to operate a steam turbine generator. Fossil fuelled power plants may also use a steam turbine generator or in the case of natural gas fired plants may use a combustion turbine. Geothermal power plants use steam extracted from hot underground rocks.

Renewable energy plants may be fuelled by waste from sugar cane, municipal solid waste, landfill methane or other forms of biomass. In integrated steel mills, blast furnace exhaust gas is of low cost although a low energy density fuel. Waste heat from industrial processes is occasionally concentrated enough to use for power generation, usually in a steam boiler and turbine.

BY PRIME MOVER

Steam turbine plants use the dynamic pressure generated by expanding steam to turn the blades of a turbine. Almost all large non hydro plants use this system. Gas turbine plants use the dynamic pressure from flowing gases to directly operate the turbine. Natural gas fuelled turbine plants can start rapidly and so are used to supply "peak" energy during periods of high demand, though at higher cost than base loaded plants. These may be comparatively small units and sometimes completely unmanned, being remotely operated. This type was pioneered by the UK, prince town being the world's first commissioned in 1959. Combined cycle plants have both a gas turbine fired by natural gas, a steam boiler and steam turbine which use the exhaust gas from the gas turbine to produce electricity. This greatly increases the overall efficiency of the plant and many new base load power plants are combined cycle plants fired by natural gas. Internal combustion Reciprocating engines are used to provide power for isolated communities and are frequently used for small cogeneration plants. Hospitals, office buildings ,industrial plants and other critical facilities also use them to provide backup power in case of a power outage. These are usually fuelled by diesel oil, heavy oil, natural gas and landfill gas. Micro turbines Sterling engine and internal combustion reciprocating engines are low cost solutions for using opportunity fuels such as landfill gas, digester gas from water treatment plants and waste gas from oil production.

Typical diagram of a coal power thermal power station1. Cooling water pump 2. Three phase transmission line 3. Step up transformer

4. Electrical generator 5. Low pressure steam 6. Boiler feed water pump 7. Surface condenser 8. Intermediate pressure steam turbine 9. Steam control valve 10.High pressure steam turbine 11.Deaerator feed water heater 12.Coal conveyer 13.Coal hopper 14.Coal pulverizer 15.Boiler steam drum 16.Boiler ash hopper 17.Super heater 18.Force draught (draft) fan 19.Reheater 20.Combustion air intake 21.Economiser 22.Airpreheater 23.Precipitator 24.Induced draught(draft) fan 25.Fuel gas stack The description of some of the components above is as follows: 1. Cooling towersCooling towers are eveporative coolers used for cooling water. Cooling tower use evaporation of water to reject heat from processes such as cooling the circulaing water used in oil refineries, chemical plants, power plants, etc. The tower vary in size from small roof top units to very large hyperboloid structures that can be upto 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 water system 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. 2. Three phase transmission lineThree phase electric power is a common method of electric power transmission. It is a type of polyphase system mainly used for power motors and many other devices. In a three phase system, three circuits reach their instantaneous peak values at different times. Taking one conductor as reference, the other two conductors are delayed in time by one-third and two-third of cycle of the electrical current. This delay between phases has the effect of giving constant power over each cycle of the current and also makes it impossible to produce a rotating magnetic field in an electric motor. At the power station, an electric generator converts mechanical power into a set of electric currents one from each electromagnetic coil or winding of the generator. The currents are sinusoidal functions of time, all at the same frequency but offset in time to give different phases. In a three phase system, the phases are spaced equally giving a phase separation of one-third of one cycle. Generators output at a voltage that ranges from hundreds of volts to 30,000 volts. At the power station, transformers steps-up this voltage for suitable transmission. After numerous further conversions in the transmission and distribution network, the power is finally transformed to standard mains voltage i.e. the household voltage. The power may already have been split into single phase at this point or it may be still three phase, where the step-down is three phase. The output of the transformer is usually star connected with the standard mains voltage being the phase neutral voltage. 3. Electrical generatorAn electrical generator is a device that coverts mechanical energy to electrical energy, using electromagnetic induction whereas electrical energy is converted to mechanical energy with the help of electric motor. The source of mechanical energy may be a reciprocating turbine steam engine. Turbines are made in variety of sizes ranging from small 1 hp(0.75 kW) used as mechanical drives for pumps, compressors and other shaft driven equipment to 2,000,000 hp(1,500,000 kW) turbines used to generate electricity.

4. Boiler Feed PumpA Boiler Feed Pump is a specific type of pump used to pump water into steam boiler. The water may be freshly supplied or retuning condensation of steam produced by the boiler. These pumps are normally high pressure units that use suction from a condensate return system and can be of centrifugal pump type or positive displacement type. Construction and Operation feed water pumps range in size up-to many horsepower and the electric motor is usually separated from the pump body by some form of mechanical coupling. Large industrial condensate pumps may also serve as the feed water pump. In either case, to force water into the boiler, the pump must generate sufficient pressure to overcome the steam pressure developed by the boiler. This is usually accomplished through the use of centrifugal pump. Feed water pumps usually run intermittently and are controlled by a float switch or other similar level-sensing device energizing the pump when it detects a lowered liquid level in the boiler substantially increased. Some pumps contain a two stage switch. As liquid lowers to the trigger point of the first stage, the pump is activated. If the liquid continues to drop (perhaps because the pump has failed, its supply has been cut-off or exhausted, or its discharge is blocked) the second stage will be triggered. This stage may switch off the boiler equipment (preventing the boiler from running dry and overheating), trigger an alarm or both.

5. Control valvesControl Valves are the valves used within industrial plants and elsewhere to control operating conditions such as temperature, pressure, flow and liquid level by fully or 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.

6. DeaeratorA Deaerator is a device for air removal and used to remove dissolved gases from boiler feed water to make it non-corrosive. A deaerator typically includes a vertical domed deaeration section as the deaeration 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 heating surfaces giving rise to localized heating and tube ruptures due to overheating. Deaerator level and pressure must be controlled by adjusting control valves-the level by regulating condensate flow and pressure by regulating steam flow. Most deaerators guarantee that if operated properly, oxygen in deaerated water will not exceed 7ppb by weight. 7. Feed Water HeaterA feed water heater is a power plant component used to pre heat water delivered to a steam generating boiler. Feed water heater improves the efficiency of the system. This reduces plant operating costs and also helps to avoid thermal shock to boiler metal when the feed water is introduced back into the steam cycle. Feed water heaters allow the feed water to be brought up-to the saturation temperature very gradually. This minimizes the inevitable irreversibility associated with heat transfer to the working fluid (water). A belt conveyer consists of two pulleys, with a continuous loop of material- the conveyer belt that rotates around them. The pulleys are powered, moving the belt and the material on the belt forward. Conveyer belts are extensively used to transport industrial and agricultural material, such as grain, coal, ores, etc.

8. PulverizerA pulverizer is a device for grinding coal for combustion in a furnace in a fossil fuel power plant.

9. Boiler Steam DrumSteam Drums are a regular feature of water tube boilers. It is reservoir of water/steam at the top end of the water tubes in the water-tube boiler. They store

the steam generated in the water tubes and act as a phase separator for the steam/water mixture. The difference in densities between hot and cold water helps in the accumulation of the hotter-water/and saturated steam into steam drum. Made from high-grade steel (probably stainless) and its working involves temperatures 390C and pressure well above 350psi (2.4MPa). The separated steam is drawn out from the top section of the drum. Saturated steam is drawn off the top of the drum. The steam will re-enter the furnace in through a super heater, while the saturated water at the bottom of steam drum flows down to the muddrum /feed water drum by down comer tubes accessories include a safety valve, water level indicator and fuse plug. A steam drum is used in the company of a mud-drum/feed water drum which is located at a lower level. So that it acts as a sump for the sludge or sediments which have a tendency to the bottom. 10. Super HeaterA Super heater is a device in a steam engine that heats the steam generated by the boiler again increasing its thermal energy and decreasing the likelihood that it will condense inside the engine. Super heaters increase the efficiency of the steam engine, and were widely adopted. Steam which has been superheated is logically known as superheated steam; non-superheated steam is called saturated steam or wet steam; Super heaters were applied to steam locomotives in quantity from the early 20th century, to most steam vehicles, and so stationary steam engines including power stations. 11. EconomizersEconomizer, or in the UK economizer, are mechanical devices intended to reduce energy consumption, or to perform another useful function like preheating a fluid. The term economizer is used for other purposes as well as boiler, power plant, heating, ventilating and air conditioning. In boilers, economizer are heat exchange devices that heat fluids , usually water, up to but not normally beyond the boiling point of the fluid. Economizers are so named because they can make use of the enthalpy and improving the boilers efficiency. They are a device fitted to a boiler which saves energy by using the exhaust gases from the boiler to preheat the cold water used the fill it (the feed water). Modern day boilers, such as those in cold fired power stations, are still fitted with economizer which is decedents of Greens

original design. In this context they are turbines before it is pumped to the boilers. A common application of economizer is steam power plants is to capture the waste hit from boiler stack gases (flue gas) and transfer thus it to the boiler feed water thus lowering the needed energy input , in turn reducing the firing rates to accomplish the rated boiler output . Economizer lower stack temperatures which may cause condensation of acidic combustion gases and serious equipment corrosion damage if care is not taken in their design and material selection.

Air Pre heaterAir pre heater is a general term to describe any device designed to heat air before another process (for example, combustion in a boiler). The purpose of the air preheater is to recover the heat from the boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat lost in the fuel gas. As a consequence, the flue gases are also sent to the flue gas stack (or chimney) at a lower temperature allowing simplified design of the ducting and the flue gas stack. It also allows control over the temperature of gases leaving the stack.
12.

13. PrecipitatorAn Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that removes particles from a flowing gas (such As air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly efficient filtration devices, and can easily remove fine particulate matter such as dust and smoke from the air steam. ESPs continue to be excellent devices for control of many industrial particulate emissions, including smoke from electricity-generating utilities (coal and oil fired), salt cake collection from black liquor boilers in pump mills, and catalyst collection from fluidized bed catalytic crackers from several hundred thousand ACFM in the largest coal-fired boiler application. The original parallel plate-Weighted wire design (described above) has evolved as more efficient ( and robust) discharge electrode designs were developed, today focusing on rigid discharge electrodes to which many sharpened spikes are attached , maximizing corona production. Transformer rectifier systems apply voltages of 50-100 Kilovolts at relatively high current densities. Modern controls minimize sparking and prevent arcing, avoiding damage to the components. Automatic

rapping systems and hopper evacuation systems remove the collected particulate matter while on line allowing ESPs to stay in operation for years at a time. 14. Fuel gas stackA Fuel gas stack is a type of chimney, a vertical pipe, channel or similar structure through which combustion product gases called fuel gases are exhausted to the outside air. Fuel gases are produced when coal, oil, natural gas, wood or any other large combustion device. Fuel gas is usually composed of carbon dioxide (CO2) and water vapour as well as nitrogen and excess oxygen remaining from the intake combustion air. It also contains a small percentage of pollutants such as particulates matter, carbon mono oxide, nitrogen oxides and sulphur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300 feet) or more, so as to disperse the exhaust pollutants over a greater aria and thereby reduce the concentration of the pollutants to the levels required by governmental environmental policies and regulations. When the fuel gases exhausted from stoves, ovens, fireplaces or other small sources within residential abodes, restaurants , hotels or other stacks are referred to as chimneys.

ELECTRICITY GENERATION
At NTPC (Badarpur) the main two paths are the flue gas or air cycle and steam or condensate paths. CAPITAL OVERHAUL NTPC has been in news due to extensive load sheds in many areas in delhi and the main cause behind these load sheds was the capital overhaul of one of 210 MW units. Unit IV was under an extensive check , which has caused shut down of the plant and the plant was dismantled completely to change the old parts and cleaning up the whole unit. But capital overhaul has no meaning because such a deep checking of the plant happens once in five to seven years. FUNCTIONING OF THE POWER PLANT In a thermal power plant one of coal, oil or natural gas is used to heat the boiler to convert the water into steam. The steam is used to turn a turbine which is

connected to a generator. When the turbine turns electricity is generated and given as output by the generator, which is then supplied to the consumers through high voltage power lines. Process of a Thermal Power Plant Detailed process of power generation in a thermal power plant: Water intake: Firstly, water is taken into the boiler through a water source. If water is available in a plenty in the region, then the source is an open pond or river. If water is scarce, then it is recycled and the same water is used over and over again. Boiler heating: The boiler is heated with the help of oil, coal or natural gas. A furnace is used to heat the fuel and supply the heat produced to the boiler. The increase in temperature helps in the transformation of water into steam. Steam Turbine: The steam generated in the boiler is sent through a steam turbine. The turbine has blades that rotate when high velocity steam flows across them. This rotation of turbine blades is used to generate electricity. Generator: A generator is connected to the steam turbine. When the turbine rotates, the generator produces electricity which is then passed on to the power distribution systems. Special mountings: There is some other equipment like the economizer and air pre heater. An economizer uses the heat from the exhaust gases to heat the feed water. An air pre heater heats the air sent into the combustion chamber to improve the efficiency of the combustion process. Ash collection system: There is a separate residue and ash collection system in place to collect all the waste materials from the combustion process and to prevent them from escaping into the atmosphere.

INTRODUCTION The operating performance of NTPC has been considerably above the national average. The availability factor for coal stations has increased from 85.03 %in 1997 98 to 90.09 %in 2006-07,which compares favourably with international standards. The LF has increased from 75.2% in 1997-98 to 89.4%during the year 2006 07 which is the highest since the inception of NTPC.

OPERATION ROOM OF THE POWER PLANT

In the Badarpur Thermal Power Station, steam is produced and used to spin a turbine that operates a generator. Water is heated turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser; this is known as a Rankine cycle. Shown here is a diagram of a conventional thermal power plant, which uses coal, oil or natural gas as fuel to boil water to produce the steam. The electricity generated at the plant is sent to consumers through high voltage power lines. The Badarpur Thermal Power plant has Steam Turbine Driven Generators which has a collective capacity of 705MW.The fuel being used is Coal which is supplied from the Jharia Coal Field in Jharkhand. Water supply is given from the Agra Canal.
Capacity of Badarpur Thermal Power Station, New Delhi Sl. No. 1. 2. Capacity 210 MW 95 MW No. of Generators 2 3 Total Capacity 420 MW 285 MW

There are basically three main units of a thermal power plant: 1. Steam Generator or Boiler 2. Steam Turbine 3. Electric Generator

1. Cooling Tower 2. Cooling Water Pump 3. Transmission Line (3 phase) 4. Unit Transformer (3 phase) 5. Electric generator (3 phase) 6. Low Pressure Turbine 7. Condensate extraction pump 8. Condenser 9. Immediate pressure turbine

10. Steam governor valve 11. High pressure Turbine 12. Deaerator 13. Feed Heater 14.Coal Conveyor 15.Coal Hopper 16. Pulverised fuel mill 17. Boiler Drum 18. Ash hopper

19. Superheater 20. Forced draught fan 21. Reheater 22. Air intake 23. Economiser 24. Air preheater 25. Precipitator 26. Induced draught fan 27. Chimney Stack

Coal is conveyed from an external stack and ground to a very fine powder by large metal spheres in the pulverised fuel mill. There it is mixed with preheated air driven by the forced draught fan .The hot air fuel mixture is forced at high pressure into the boiler where it rapidly ignites. Water of a high purity flows vertically up the tube lined walls of the boiler, where it turns into steam and is passed to the boiler drum where steam is separated from any remaining water. The steam passes through a manifold in the roof of the drum into the pendant superheater where its temperature and pressure increase rapidly to around 200 bar and 540 C sufficient to make the tube walls glow a dull red. The steam is piped to the high pressure turbine, the first of a three stage turbine process. A steam governor valve allows for both manual control of the turbine and automatic set point following. The steam is exhausted from the high pressure turbine and reduced in both pressure and temperature is returned to the boiler reheater. The reheated steam is then passed to the intermediate pressure turbine, and from there passed directly to the low pressure turbine set. The exiting steam, now a little above its boiling point is brought into thermal contact with cold water (pumped in from the cooling tower) in the condenser, where it condenses rapidly back into water creating near vacuum like conditions inside the condenser chest. The condensed water is then passed by a feed pump through a deaerator, and pre warmed, first in a feed heater powered by steam

drawn from the high pressure set and then in the economiser, before being returned to the boiler drum. The cooling water from the condenser is sprayed inside a cooling tower, creating a highly visible plume of water vapour before being pumped back to the condenser in cooling water cycle. The three turbine sets are sometimes coupled on the same shaft as the three phase electrical generator which generates an intermediate level voltage (typically 20 25 kV).This is stepped up by the unit transformer to a voltage more suitable for transmission (typically 250-500 kV) and is sent out onto the three phase transmission system. Exhaust gas from the boiler is drawn by the induced draft fan through an electrostatic precipitator and is then vented through the chimney stack.

Steam Generator or Boiler The boiler is a rectangular furnace about 50 ft (15 m)on a side and 130 ft (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60 mm)in diameter. Pulverized coal is air blown into the furnace from fuel nozzles at the four corners and it rapidly burns forming a large fireball at the center. The thermal radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three to four times the throughput and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700 F (370 C) and 3,200 psi (22.1 M a).It is separated from the water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1,000 F (540 C) to prepare it for the turbine. The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. The generator includes the economizer, the steam drum, the chemical dosing equipment and the furnace with its steam generating tubes and the superheater coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include forced draft (FD)fan, air preheater (A H),boiler furnace, induced draft (ID)fan, fly ash collectors (electrostatic precipitator or bag-house)and the flue gas stack.

For units over about 210 MW capacity redundancy of key components is provided by installing duplicates of the FD fan, A H, fly ash collectors and ID fan with isolating dampers. On some units of about 60 MW, two boilers per unit may instead be provided. Boiler Furnace and Steam Drum Once water enters inside the boiler or steam generator the process of adding the latent heat of vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical reaction of burning some type of fuel. The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to the steam drum. Once the water enters the steam drum it goes down the down comers to the lower inlet water wall headers. From the inlet headers the water rises through the water walls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear water walls (typically).As the water is turned into steam/vapour in the water walls, the steam/vapour once again enters the steam drum. The steam/vapour is passed through a series of steam and water separators and then dryers inside the steam drum. The steam separators and dryers remove the water droplets from the steam and the cycle through the water walls is repeated. This process is known as natural circulation. The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers, water lancing and observation ports (in the furnace walls) for observation of the furnace interior. Furnace explosions due to any accumulation of combustible gases after a trip out are avoided by flushing out such gases from the combustion zone before igniting the coal. The steam drum (as well as the superheater coils and headers) have air vents and drains needed for initial start up. The steam drum has an internal device that removes moisture from the wet steam entering the drum from the steam generating tubes. The dry steam then flows into the superheater coils. Geothermal plants need no boiler since they use naturally occurring steam sources. Heat exchangers may be used where the geothermal steam is very corrosive or contains excessive suspended solids. Nuclear plants also boil water to raise steam either directly passing the working steam through the reactor or else using an intermediate heat exchanger.

Fuel Preparation System

In coal fired power stations,the raw feed coal from the coal storage area is first crushed into small pieces and then conveyed to the coal feed hoppers at the boilers.The coal is next pulverized into a very fine powder.The pulverizers may be ball mills,rotating drum grinders,or other types of grinders. Some power stations burn fuel oil rather than coal.The oil must kept warm (above its pour point)in the fuel oil storage tanks to prevent the oil from congealing and becoming unpumpable. The oil is usually heated to about 100 C before being pumped through the furnace fuel oil spray nozzles. Boilers in some power stations use processed natural gas as their main fuel.Other power stations may use processed natural gas as auxiliary fuel in the event that their main fuel supply (coal or oil)is interrupted.In such cases,separate gas burners are provided on the boiler furnaces.

Fuel Firing System and Igniter

From the pulverized coal bin, coal is blown by hot air through the furnace coal burners at an angle which imparts a swirling motion to the powdered coal to enhance mixing of the coal powder with the incoming preheated combustion air and thus to enhance the combustion. To provide sufficient combustion temperature in the furnace before igniting the powdered coal, the furnace temperature is raised by first burning some light fuel oil or processed natural gas (by using auxiliary burners and igniters provide for that purpose). Air Path External fans are provided to give sufficient air for combustion. The forced draft fan takes air from the atmosphere and first warming it in the air preheater for better combustion, injects it via the air nozzles on the furnace wall. The induced draft fan assists the FD fan by drawing out combustible gases from the furnace, maintaining a slightly negative pressure in the furnace to avoid backfiring through any opening. At the furnace outlet and before the furnace gases are handled by the ID fan, fine dust carried by the outlet gases is removed to avoid

atmospheric pollution. This is an environmental limitation prescribed by law and additionally minimizes erosion of the ID fan.

Auxiliary Systems
Fly Ash Collection

Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators or bag filters. Generally the fly ash is pneumatically transported to storage silos for subsequent transport by trucks or railroad cars.
Bottom Ash Collect on and Disposal

At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from the bottom of the furnace. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement is included to crush the clinkers and for conveying the crushed clinkers and bottom ash to a storage site.
Boiler Make-up Water Treatment Plant and Storage

Since there is continuous withdrawal of steam and continuous return of condensate to the boiler, losses due to blow down and leakages have to be made up for so as to maintain the desired water level in the boiler steam drum.For this,continuous make up water is added to the boiler water system.The impurities in the raw water input to the plant generally consist of calcium and magnesium salts which impart hardness to the water.Hardness in the make up water to the boiler will form deposits on the tube water surfaces which will lead to overheating and failure of the tubes.Thus,the salt s have to be removed from the wa t e r and that is done by a water demineralising treatment plant (DM). A DM plant generally consists of cation,anion and mixed be dexchangers. The f inal water from this process consists essentially of hydrogen ions and hydroxide ions which is the chemical composition of pure water.The DM water,being very pure,becomes highly corrosive once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen absorption. The capacity of the DM plant is dictated by the type and quantity of salts in the raw water input.

However ,some storage is essential as the DM plant may be down for maintenance.For this purpose,a storage tank is installed from which DM water is continuously withdrawn for boiler make up.The storage tank for DM water is made from materials not affected by corrosive water, such as VC.The piping and valves are generally of stainless steel .Sometimes, a steam blanketing arrangement or stainless steel doughnut float is provided on top of the water in the tank to avoid contact with atmospheric air.DM water make up is generally added at the steam space o f the surf ace condenser (i.e.,the vacuum side).This arrangement not only sprays the water but also DM water gets deaerated, with the dissolved gases be ingore moved by the ejector of the condenser itself. Steam Turbine Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators,which produce electricity.The turbines themselves are driven by steam generated in 'Boilers'or 'Steam Generators'as they are sometimes called. 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 stages with each stage consisting of a stationary blade (or nozzle)and a rotating blade.Stationary blades convert the potential energy of the steam (temperature and pressure)into kinetic energy (velocity)and direct the flow onto the rotating blades.The rotating blades convert the 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.The rotational speed is 3000 rpm for Indian System (50 Hz)systems and 3600 for American (60 Hz)systems. In a typical larger power stations,the steam turbines are split into three separate stages,the first being the High ressure (H ),the second the Intermediate ressure (I ) and the third the Low Pressure (L )stage,where high,intermediate and low describe the pressure of the steam. After the steam has passed through the H stage,it is returned to the boiler to be re heated to its original temperature although the pressure remains greatly reduced.The reheated steam then passes through the I stage and finally to the L stage of the turbine. A distinction is made between "impulse"and "reaction"turbine designs based on the relative pressure drop across the stage.There are two measures for pressure drop,the pressure ratio and the percent reaction.ressure ratio is the pressure at the

stage exit divided by the pressure at the stage entrance.Reaction is the percentage isentropic enthalpy drop across the rotating blade or bucket compared to the total stage enthalpy drop.Some manufacturers utilise percent pressure drop across stage to define reaction. Steam turbines can be configured in many different ways.Several I or L stages can be incorporated into the one steam turbine.A single shaft or several shafts coupled together may be used.Either way,the principles are the same for all steam turbines.The configuration is decided by the use to which the steam turbine is put,co generation or pure electricity production.For co generation,the steam pressure is highest when used as process steam and at a lower pressure when used for the secondary function of electricity production. Nozzles and Blades Steam enthalpy is converted into rotational energy as it passes through a turbine stage.A turbine stage consists of a stationary blade (or nozzle)and a rotating blade (or bucket).Stationary blades convert the potential energy of the steam (temperature and pressure)into kinetic energy (velocity)and direct the flow onto the rotating blades.The rotating blades convert the kinetic energy into impulse and reaction forces caused by pressure drop,which results in the rotation of the turbine shaft or rotor. Steam turbines are machines which must be designed,manufactured and maintained to high tolerances so that the design power output and availability is obtained.They are subject to a number of damage mechanisms,with two of the most important being: Erosion due to Moisture -The presence of water droplets in the last stages of a turbine causes erosion to the blades.This has led to the imposition of an allowable limit of about 12% wetness in the exhaust steam; Solid Particle Erosion -The entrainment of erosive materials from the boiler in the steam causes wear to the turbine blades. Cogeneration Cycles - In cogeneration cycles,steam is typically generated at a higher temperature and pressure than required for a particular industrial process.The steam is expanded through a turbine to produce electricity and the

resulting extractions at the discharge are at the temperature and pressure required by the process. Turbines can be condensing or non condensing design typically with large mass flows and comparably low output.Traditionally,pressures were 6.21 M a and below with temperatures 441 C or lower,although the trend towards higher levels of each continues. There are now a considerable number of co generation steam turbines with initial steam pressures in the 8.63 to 10 M a range and steam temperatures of 482 to 510 C.

Bearings and Lubrication Two types of bearings are used to support and locate the rotors of steam turbines: JOURNAL BEARINGS Journal bearings are used to support the weight of the turbine rotors.A journal bearing consists of two half cylinders that enclose the shaft and are internally lined with Babbitt,a metal alloy usually consisting of tin,copper and antimony;and THRUST BEARINGS Thrust bearings axially locate the turbine rotors.A thrust bearing is made up of a series of Babbitt lined pads that run against a locating disk attached to the turbine rotor. High pressure oil is injected into the bearings to provide lubrication.The oil is carefully filtered to remove solid particles.Specially designed centrifuges remove any water from the oil. Shaft Seals The shaft seal on a turbine rotor consist of a series of ridges and groves around the rotor and its housing which present a long,tortuous path for any steam leaking through the seal.The seal therefore does not prevent the steam from leaking,merely reduces the leakage to a minimum. The leaking steam is collected and returned to a low pressure part of the steam circuit . Turning Gear Large steam turbines are equipped with "turning gear"to slowly rotate the turbines after they have been shut down and while they are cooling.This evens out the temperature distribution around the turbines and prevents bowing of the rotors.

Vibration The balancing of the large rotating steam turbines is a critical component in ensuring the reliable operation of the plant.Most large steam turbines have sensors installed to measure the movement of the shafts in their bearings.This condition monitoring can identify many potential problems and allows the repair of the turbine to be planned before the problems become serious.

Electric Generator The steam turbine driven generators have auxiliary systems enabling them to work satisfactorily and safely. The steam turbine generator being rotating equipment generally has a heavy, large diameter shaft.The shaft therefore requires not only supports but also has to be kept in position while running.To minimize the frictional resistance to the rotation,the shaft has a number of bearings.The bearing shells,in which the shaft rotates,are lined with a low friction material like Babbitt metal.Oil lubrication is provided to further reduce the friction between shaft and bearing surface and to limit the heat generated. Barring Gear (or Turning Gear) Barring gear is the term used for the mechanism provided for rotation of the turbine generator shaft at a very low speed (about one revolution per minute)after unit stoppages for any reason. Once the unit is "tripped"(i.e.,the turbine steam inlet valve is closed),the turbine starts slowing or "coasting down".When it stops completely,there is a tendency for the turbine shaft to deflect or bend if allowed to remain in one position too long.This deflection is because the heat inside the turbine casing tends to concentrate in the top half of the casing,thus making the top half portion of the shaft hotter than the bottom half.The shaft therefore warps or bends by millionths of inches,only detectable by monitoring eccentricity meters. But this small amount of shaft deflection would be enough to cause vibrations and damage the entire steam turbine generator unit when it is restarted.Therefore,the shaft is not permitted to come to a complete stop by a mechanism known as "turning gear"or "barring gear"that automatically takes over to rotate the unit at a preset low speed. If the unit is shut down for major maintenance,then the barring

gear must be kept in service until the temperatures of the casings and bearings are sufficiently low.

Condenser The surface condenser is a shell and tube heat exchanger in which cooling water is circulated through the tubes.The exhaust steam from the low pressure turbine enters the shell where it is cooled and converted to condensate (water)by flowing over the tubes as shown in the adjacent diagram.Such condensers use steam ejectors or rotary motor driven exhausters for continuous removal of air and gases from the steam side to maintain vacuum. For best efficiency,the temperature in the condenser must be kept as low as practical in order to achieve the lowest possible pressure in the condensing steam.Since the condenser temperature can almost always be kept significantly below 100 C where the vapor pressure of water is much less than atmospheric pressure,the condenser generally works under vacuum.Thus leaks of non condensible air into the closed loop must be prevented.lants operating in hot climates may have to reduce output if their source of condenser cooling water becomes warmer;unfortunately this usually coincides with periods of high electrical demand for air conditioning. The condenser generally uses either circulating cooling water from a cooling tower to reject waste heat to the atmosphere,or once through water from a river,lake or ocean. Feedwater Heater A Rankine cycle with a two stage steam turbine and a single feedwater heater. In the case of a conventional steam electric power plant utilizing a drum boiler,the surface condenser removes the latent heat of vaporization from the steam as it changes states from vapour to liquid.The heat content (btu)in the steam is referred to as Enthalpy.The condensate pump then pumps the condensate water through a feedwater heater.The feedwater heating equipment then raises the temperature of the water by utilizing extraction steam from various stages of the turbine. A

Rankine cycle with a two stage steam turbine and a single feedwater heater reheating the feedwater reduces the irreversibilities involved in steam generation and therefore improves the thermodynamic efficiency of the system. This reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when the feedwater is introduced back into the steam cycle.

Superheater As the steam is conditioned by the drying equipment inside the drum,it is piped from the upper drum area into an elaborate set up of tubing in different areas of the boiler.The areas known as superheater and reheater.The steam vapor picks up energy and its temperature is now superheated above the saturation temperature.The superheated steam is then piped through the main steam lines to the valves of the high pressure turbine. Deaerator A steam generating boiler requires that the boiler feed water should be devoid of air and other dissolved gases,particularly corrosive ones,in order to avoid corrosion of the metal. Generally,power stations use a deaerator to provide for the removal of air and other dissolved gases from the boiler feedwater.A deaerator typically includes a vertical,domed deaeration section mounted on top of a horizontal cylindrical vessel which serves as the deaerated boiler feedwater storage tank.

CONTROL AND INSTRUMENTATION

This division basically calibrates various instruments and takes care of any faults occur in any of the auxiliaries in the plant. This department is the brain of the plant because from the relays to transmitters followed by the electronic computation chipsets and recorders and lastly the controlling circuitry, all fall under this. Instrumentation can be well defined as a technology of using instruments to measure and control the physical and chemical properties of a material. Control and instrumentation has following labs: Manometry lab Protection and interlocks lab Automation lab Electronics lab Water treatment plant Furnaces Safety Supervisory System Lab MANOMETRY LAB TransmittersTransmitter is used for pressure measurements of gases and liquids, its working principle is that the input pressure is converted into electrostatic

capacitance and from there it is conditioned and amplified. It gives an output of 4-20 ma DC. It can be mounted on a pipe or a wall. For liquid or steam measurement transmitters is mounted below main process piping and for gas measurement transmitter is placed above pipe. ManometerIts a tube which is bent, in U shape. It is filled with a liquid. This device corresponds to a difference in pressure across the two limbs. Bourdon Pressure GaugeIts an oval section tube. Its one end is fixed. It is provided with a pointer to indicate the pressure on a calibrated scale. It is of two types : (a) Spiral type : for low pressure measurement, and (b) Helical type : for high pressure measurement PROTECTION AND INTERLOCK LAB InterlockingIt is basically interconnecting two or more equipments so that if one equipments fails other one can perform the tasks. This type of interdependence is also created so that equipments connected together are started and shut down in the specific sequence to avoid damage. For protection of equipments tripping are provided for all the equipments. Tripping can be considered as the series of instructions connected through OR GATE. The main equipments of this lab are relay and circuit breakers. Some of the instrument uses for protection are: RELAY It is a protective device. It can detect wrong condition in electrical circuits by constantly measuring the electrical quantities flowing under normal and faulty conditions. Some of the electrical quantities are voltage, current, phase angle and velocity. FUSES It is a short piece of metal inserted in the circuit, which melts when heavy current flows through it and thus breaks the circuit. Usually silver is used as a fuse material because:

a) The coefficient of expansion of silver is very small. As a result no critical fatigue occurs and thus the continuous full capacity normal current ratings are assured for the long time. b) The conductivity of the silver is unimpaired by the surges of the current that produces temperatures just near the melting point. c) Silver fusible elements can be raised from normal operating temperature to vaporization quicker than any other material because of its comparatively low specific heat. MCBs (Miniature Circuit Breakers)They are used with combination of the control circuits to a) Enable the staring of plant and distributors b) Protect the circuit in case of a fault. It consists of current carrying contacts, one movable and other fixed. When a fault occurs the contacts separate and are is stuck between them. There are three types of trips MANUAL TRIP THERMAL TRIP SHORT CIRCUIT TRIP. Protection and Interlock System1. HIGH TENSION CONTROL CIRCUIT For high tension system the control system are excited by separate D.C supply. For starting the circuit conditions should be in series with the starting coil of the equipment to energize it. Because if even a single condition is not true then system will not start. 2. LOW TENSION CONTROL CIRCUIT For low tension system the control circuits are directly excited from the 0.415 KV A.C supply. The same circuit achieves both excitation and tripping. Hence the tripping coil is provided for emergency tripping if the interconnection fails. AUTOMATION LAB This lab deals in automating the existing equipment and feeding routes. Earlier,the old technology dealt with only (DAS) Data Acquisition System and came to be known as primary systems. The modern technology or the secondary systems are coupled with (MIS) Management Information System. But this lab universally applies the pressure measuring instruments as the

controlling force. However, the relays are also provided but they are used only for protection and interlocks. ELECTRONICS LAB This lab undertakes the calibration and testing of various cards. It houses various types of analytical instruments like oscilloscopes, integrated circuits, cards auto analyzers etc.Various processes undertaken in this lab are: 1. Transmitter converts mV to mA. 2. Auto analyzer purifies the sample before it is sent to electrodes. It extracts the magnetic portion. PYROMETRY LAB Liquid in glass thermometer - Mercury in the glass thermometer boils at 340 degree Celsius which limits the range of temperature that can be measured. It is L shaped thermometer which is designed to reach all inaccessible places. Ultra violet censorThis device is used in furnace and it measures the intensity of ultra violet rays there and according to the wave generated which directly indicates the temperature in the furnace. ThermocouplesThis device is based on SEEBACK and PELTIER effects. It comprises of two junctions at different temperature. Then the emf is induced in the circuit due to the flow of electrons. This is an important part in the plant. RTD(Resistance temperature detector) It performs the function of thermocouple basically but the difference is of a resistance. In this due to the change in the resistance the temperature difference is measured. In this lab, also the measuring devices can be calibrated in the oil bath or just boiling water (for low range devices) and in small furnace (for high range devices). FURNACE SAFETY AND SUPERVISORY SYSTEM LAB

This lab has the responsibility of starting fire in the furnace to enable the burning of coal. For first stage coal burners are in the front and rear of the furnace and for the second and third stage corner firing is employed. Unburnt coal is removed using forced draft or induced draft fan. The temperature inside the boiler is 1100 degree Celsius and its height is 18 to 40 m. It is made up of mild steel. An ultra violet sensor is employed in furnace to measure the intensity of ultra violet rays inside the furnace and according to it a signal in the same order of same mV is generated which directly indicates the temperature of the furnace. For firing the furnace a 10 KV spark plug is operated for ten seconds over a spray of diesel fuel and pre-heater air along each of the feeder-mills. The furnace has six feeder mills each separated by warm air pipes fed from forced draft fans. In first stage indirect firing is employed that is feeder mills are not fed directly from coal but are fed from three feeders but are fed from pulverized coalbunkers. The furnace can operate on the minimum feed from three feeders but under not circumstances should any one be left out under operation, to prevent creation of pressure different with in the furnace, which threatens to blast it. AUTOMATION AND CONTROL SYSTEM The word automation is widely used today in relation to various types of applications, such as office automation, plant or process automation. This subsection presents the application of a control system for the automation of a process / plant, such as a power station. In this last application, the automation actively controls the plant during the three main phases of operation: plant start-up, power generation in stable or put During plant startup and shut-down, sequence controllers as well as long range modulating controllers in or out of operation every piece of the plant, at the correct time and in coordinated modes, taking into account safety as well as overstressing limits. During major load changes, the automation system automatically redefines new set points and switches ON or OFF process pieces, to automatically bring the individual processes in an optimally coordinated way to the new desired load demand. This load transfer is executed according to pre- programmed adaptively controlled load gradients and in a safe way. AUTOMATION: THE BENEFITS

The main benefits of plant automation are to increase overall plant availability and efficiency. The increase of these two factors is achieved through a series of features summarized as follows: Optimisation of house load consumption during plant start- up, shut-down and operation, via:

Faster plant start-up through elimination of control errors creating delays. Faster sequence of control actions compared to manual ones. Even a welltrained operator crew would probably not be able to bring the plant to full load in the same time without considerable risks. Co-ordination of house load to the generated power output.

Ensure and maintain plant operation (even in case of disturbances in the control system) via:

Coordinated ON / OFF and modulating control switchover capability from a sub process to a redundant one. Following a process component trip to prevent sub-process and process tripping chain reaction. Reduce plant / process shutdown time for repair and maintenance as well as repair costs, via:

Protection of individual process components against overstress (in a stable or unstable plant operation). Bringing processes in a safe stage of operation, where process components are protected against overstress. PROCESS STRUCTURE Analysis of processes in Power Stations and Industry advocates the advisability of dividing the complex overall process into individual subprocesses having distinctly defined functions. This division of the process in clearly defined groups, termed as FUNCTIONAL GROUPS, results in a hierarchical process structure. While the hierarchical structure is governed in the horizontal direction by the number of drives (motorised valves, fans, dampers, pumps, etc.) in other words the size of the process; in the vertical

direction, there is a distinction made between three fundamental levels, these being the: Drive Level Function Group Level Unit Level. To the Drive Level, the lowest level, belong the individual process equipment and associated electrical drives. The Function Group is that part of the process that fulfils a particular defined task e.g., Induced Draft Control, Feed Water Control, Blooming Mill Control, etc. Thus at the time of planning it is necessary to identify each function group in a clear manner by assigning it to a particular process activity. Each function group contains a combination of its associated individual equipment drives. The drive levels are subordinate to this level. The function groups are combined to obtain the overall process control function at the Unit Level. CONTROL SYSTEM STRUCTURE The primary requirement to be fulfilled by any control system architecture is that it be capable of being organized and implemented on true processoriented lines. In other words, the control system structure should map on to the hierarchy process structure. SYSTEM OVERVIEW The control and automation system used here is a micro based intelligent multiplexing system This system, designed on a modular basis, allows to tighten the scope of control hardware to the particular control strategy and operating requirements of the process Regardless of the type and extent of process to control provides system uniformity and integrity for:

Signal conditioning and transmission Modulating controls

CONTROL AND MONITORING MECHANISMS There are basically two types of Problems faced in a Power Plant Metallurgical Mechanical Mechanical Problemcan be related to Turbines that is the max speed permissible for a turbine is 3000 rpm , so speed should be monitored and maintained at that level Metallurgical Problem can be view as the max Inlet Temperature for Turbile is 1060 oC so temperature should be below the limit. Monitoring of all the parameters is necessary for the safety of both: Employees Machines So the Parameters to be monitored are : Speed Temperature Current Voltage Pressure Eccentricity Flow of Gases Vaccum Pressure Valves Level Vibration PRESSURE MONITORING

Pressure can be monitored by three types of basic mechanisms Switches Gauges Transmitter type For gauges we use Bourden tubes : The Bourdon Tube is a non liquid pressure measurement device. It is widely used in applications where inexpensive static pressure measurements are needed. A typical Bourdon tube contains a curved tube that is open to external pressure input on one end and is coupled mechanically to an indicating needle on the other end, as shown schematically below.

Typical Bourdon Tube Pressure Gages

For Switches pressure swithes are used and they can be used for digital means of monitoring as swith being ON is referred as high and being OFF is as low. All the monitored data is converted to either Current or Voltage parameter. The Plant standard for current and voltage are as under Voltage : 0 10 Volts range Current : 4 20 milliAmperes We use 4mA as the lower value so as to check for disturbances and wire breaks. Accuracy of such systems is very high . ACCURACY : + - 0.1 % The whole system used is SCADA baseD.

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

Pressure Electricity Start HL switch Level low Pressure in line Level High High level Electricity pump Stop Pressure
LL switch

AN D

OR

Electricity BASIC PRESSURE CONTROL MECHANISM

TEMPERATURE MONITORING
Thernocouples or RTDs are used for temperature monitoring Normally RTDs are used for low temperatures. Thermocouple selection depends upon two factors:

 Temperature Range Accuracy Required Normally used Thermocouple is K Type Thermocouple: Chromel (Nickel-Chromium Alloy) / Alumel (Nickel-Aluminium Alloy) This is the most commonly used general purpose thermocouple. It is inexpensive and, owing to its popularity, available in a wide variety of probes. They are available in the 200 C to +1200 C range. Sensitivity is approximately 41 V/C. RTDs are also used but not in protection systems due to vibrational errors. A constant current is passed through the RTD. So that if R changes then the Voltage also changes. RTDs used in Industries are Pt100 and Pt1000 Pt100 : 0 0C 100 ( 1 = 2.5 0C ) Pt1000 : 0 0C - 1000 Pt1000 is used for higher accuracy The gauges used for Temperature measurements are mercury filled Temperature gauges. For Analog medium, thermocouples are used and for Digital medium, switches are used which are basically mercury switches.

FLOW MEASUREMENT Flow measurement does not signify much and is measured just for metering purposes and for monitoring the processes ROTAMETERS: A Rotameter is a device that measures the flow rate of liquid or gas in a closed tube. It belongs to a class of meters called variable area meters, which measure flow rate by allowing the cross sectional area the fluid travels through to vary, causing some measurable effect.

A rotameter consists of a tapered tube, typically made of glass, with a float inside that is pushed up by flow and pulled down by gravity. At a higher flow rate more area (between the float and the tube) is needed to accommodate the flow, so the float rises. Floats are made in many different shapes, with spheres and spherical ellipses being the most common. The float is shaped so that it rotates axially as the fluid passes. This allows you to tell if the float is stuck since it will only rotate if it is not. For Digital measurements Flap system is used. For Analog measurements we can use the following methods : Flowmeters Venurimeters / Orifice meters Turbines Massflow meters ( oil level ) Ultrasonic Flow meters Magnetic Flowmeter ( water level ) Selection of flow meter depends upon the purpose , accuracy and liquid to be measured so different types of meters used. Turbine type are the simplest of all. They work on the principle that on each rotation of the turbine a pulse is generated and that pulse is counted to get the flow rate. VENTURIMETERS

Referring to the diagram, using Bernoulli's equation in the special case of incompressible fluids (such as the approximation of a water jet), the theoretical pressure drop at the constriction would be given by (/2)(v22 - v12).

And we know that rate of flow is given by: Flow = k (D.P) Where DP is Differential Presure or the Pressure Drop. CONTROL VALVES A valve is a device that regulates the flow of substances (either gases, fluidized solids, slurries, or liquids) by opening, closing, or partially obstructing various passageways. Valves are technically pipe fittings, but usually are discussed separately. Valves are used in a variety of applications including industrial, military, commercial, residential, transportation. Plumbing valves are the most obvious in everyday life, but many more are used. Some valves are driven by pressure only, they are mainly used for safety purposes in steam engines and domestic heating or cooking appliances. Others are used in a controlled way, like in Otto cycle engines driven by a camshaft, where they play a major role in engine cycle control. Many valves are controlled manually with a handle attached to the valve stem. If the handle is turned a quarter of a full turn (90) between operating positions, the valve is called a quarter-turn valve. Butterfly valves, ball valves, and plug valves are often quarter-turn valves. Valves can also be controlled by devices called actuators attached to the stem. They can be electromechanical actuators such as an electric motor or solenoid, pneumatic actuators which are controlled by air pressure, or hydraulic actuators which are controlled by the pressure of a liquid such as oil or water. So there are basically three types of valves that are used in power industries besides the handle valves. They are : Pneumatic Valves they are air or gas controlled which is compressed to turn or move them Hydraulic valves they utilize oil in place of Air as oil has better compression Motorised valves these valves are controlled by electric motors FURNACE SAFEGUARD SUPERVISORY SYSTEM

FSSS is also called as Burner Management System (BMS). It is a microprocessor based programmable logic controller of proven design incorporating all protection facilities required for such system. Main objective of FSSS is to ensure safety of the boiler. The 95 MW boilers are indirect type boilers. Fire takes place in front and in rear side. Thats why its called front and rear type boiler. The 210 MW boilers are direct type boilers (which means that HSD is in direct contact with coal) firing takes place from the corner. Thus it is also known as corner type boiler. IGNITER SYSTEM Igniter system is an automatic system, it takes the charge from 110kv and this spark is brought in front of the oil guns, which spray aerated HSD on the coal for coal combustion. There is a 5 minute delay cycle before igniting, this is to evacuate or burn the HSD. This method is known as PURGING. PRESSURE SWITCH Pressure switches are the devices that make or break a circuit. When pressure is applied , the switch under the switch gets pressed which is attached to a relay that makes or break the circuit. Time delay can also be included in sensing the pressure with the help of pressure valves. Examples of pressure valves: Manual valves (tap) Motorized valves (actuator) works on motor action Pneumatic valve (actuator) _ works due to pressure of compressed air Hydraulic valve