Documente Academic
Documente Profesional
Documente Cultură
Submitted By:-
Shivani Chhabra
7225
ECE-2(5th sem)
ABOUT THE COMPANY
CORPORATE VISION :
“A world class integrated power major, powering India's growth with
increasing global presence.”
CORE VALUES :
B- Business ethics
C-Customer focus
O-Organisational & professional pride
M-Mutual respect & trust
I-Innovation & speed
T-Total quality for excellence
Type Public
Founded 1975
Headquart
Delhi, India
ers
R S Sharma, Chairman & Managing
Key people
Director
Industry Electricity generation
Products Electricity
▲INR 416.37 billion (2008) or USD
Revenue
18.15 billion
Net ▲INR 70.47 billion (2008) or USD
income 1.89 billion
Employees 23867 (2006)
Website http://www.ntpc.co.in
EVOLUTION OF NTPC
NTPC was set up in 1975 with 100% ownership by the
1975 Government of India. In the last 30 years, NTPC has grown
into the largest power utility in India.
NTPC is the largest power utility in India, accounting for about 20% of
India’s installed capacity.
THERMAL POWER PLANT
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 or befouls 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. Typical diagram of a coal power thermal power
station-
3. Electrical generator-
An 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 Pump-
A 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 upto
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 detect 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 valves-
Control 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. Deaerator-
A 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.
8. Pulverizer-
A pulverizer is a device for grinding coal for combustion in a furnace in
a fossil fuel power plant.
11. Economizers-
Economizer, 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. Boiler, power plant, and 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 boiler’s 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 Green’s 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.
13. Precipitator-
An 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. ESP’s 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
ESP’s to stay in operation for years at a time.
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.
COAL TO STAEM
Its other raw materials are air and water. The coal brought to the station by trains or by
other means, travels handling plant by conveyer belts, travels from pulverizing mills,
which grind it as fine as the face powder of size upto 20 microns. The finely produced
coal mixed with preheated air is then blown into the boiler by a fan called primary air fan
where it burns more like a gas than as a solid, in the conventional domestic or industrial
grate, with additional amount of air, called secondary air supply, by forced draft fan.
As coal is ground so finally the resultant ash is also a fine powder. Some of it binds
together to form pumps, which falls into ash pits at the bottom of the furnace. The water-
quenched ash from the bottom is conveyed to pits for subsequent disposal or sale. Most
of ash, still in fine partical form is carried out of boilers to the precipitator as dust, where
electrodes charged with high voltage electricity trap it. The dust is then conveyed to water
to disposal area or to bunker for sale while the clean flue gases are passed on through IP
fans to be discharged through chimneys.
The heat released from the coal has been absorbed by the many kilometers tubing which
line the boiler walls. Inside the tubes the boiler feed water, which is transformed by heat
into staemat high temperature and pressure.. The steam superheated in further tubes
(superheaters) passes to turbine where it is discharged through the nozzle on the turbine
blades. Just as the energy of wind turns the sail of the windmill, the energy of steam
striking the blade makes the turbine rotate.
Coupled to the end of the turbine is the rotor of the generator. The rotor is housed inside
the stator having heavy coils of the bars in which electricity is produced through the
movement of magnetic field created by the rotor. Electricity passes from stator windings
to step-up transformer which increases its voltage so that it can be transmited efficiently
over lines of grid.
The staem which has given up its heat energy is cahnged back into water in a condenser
so that it is ready for re-use. The condenser contains many kilometers of tubing through
which cold water is constantly pumped. The staem passing around the tubes looses
heat.Thus it is rapidly changed back into water.
But, the two lots of water, that is, the boiler feed and cooling water must never mix.
Cooling water is drawn from river- bed, but the boiler feed water must be absolutely pure,
far purer than the water we drink (de-mineralized water), otherwise it may damage the
boiler tubes.
TABLES OF CYCLES
COAL CYCLE
CONDENSATE CYCLE
FEED WATER CYCLE
STEAM CYCLE
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.
1. Manometry lab
• Transmitters- Transmitter 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.
• Manometer- It’s 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.
• Bourden Pressure Gauge- It’s 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
2. Protection and Interlock Lab
• Interlocking- It 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. When The main equipments of this lab
are relay and circuit breakers. Some of the instrument uses for protection are: 1.
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. 2. 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.
• Miniature Circuit Breaker- 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. In 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 -MANUAL TRIP - THERMAL TRIP - SHORT CIRCUIT TRIP.
• Protection and Interlock System- 1. 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.
3. 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.
4. 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 censor- This 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.
• Thermocouples - This device is based on SEEBACK and PELTIER effect. 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).
5. 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.
6. 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.
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 start-up 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 stable generation of power, the modulating portion of the automation system
keeps the actual generated power value within the limits of the desired load demand.
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.
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:
Reduce plant / process shutdown time for repair and maintenance as well as
repair costs, via:
PROCESS STRUCTURE
Analysis of processes in Power Stations and Industry advocates the advisability of
dividing the complex overall process into individual sub-processes 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.
The above three levels are defined with regard to the process and not from the control
point of view.
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:
Modulating controls
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
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.
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
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 heardt of
Instrumentation .
Pressure
HL switch AN
Electricity Start D
Level low Pressure in line
Level HighLL switch
High level
pump
Electricity Stop OR
Pressure
Electricity
TEMPERATURE MONITORING
We can use Thernocouples or RTDs for temperature monitoring
Normally RTDs are used for low temperatures.
Temperature Range
Accuracy Required
RTDs are also used but not in protection systems due to vibrational errors.
We pass a constant curre t through the RTD. So that if R changes then the Voltage also
changes
The gauges used for Temperature measurements are mercury filled Temperature gauges.
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 is
occasionally misspelled as 'rotometer'.
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.
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 (ρ/2)(v22 - v12).
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.
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
The 95 MW boilers are indirect type boilers. Fire takes place in front and in rear side.
That’s 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:
1. Manual valves (tap)
4. Hydraulic valve