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ROHIT KUMAR ECE (7th Sem) ABES IT ,Ghaziabad Roll No. 0829031414
TABLE OF CONTENT
1. ACKNOWLEDGEMENT
2. TRAINING CERTIFICATE 3. ABOUT THE COMPANY 4. 5. 6. :::::7. BRIEF HISTORY OF THE POWER PLANT (BADARPUR) THERMAL POWER PLANT CONTROL & INSTRUMENTATION
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Manometry lab Protection and interlocks lab Automation lab Electronics lab Water treatment plant Furnaces Safety Supervisory System Lab INFORMATION AND TECHNOLOGY
ACKNOW LEDGEM ENT I hereby take this opportunity to thank NTPC Ltd. Badarpur for giving me this opportunity to conduct my training in NTPC Ltd., Badarpur. I am grateful to Sudhir Kumar (P&S) for allowing me to conduct Mr. my training in the control & Instrumentation department. I am heartly indebted tofaculty for the providing me with detailed in depth knowledge very useful information about the processes and and systems used in theplant. Their support was instrumental in my training being fruitful . I very also am thankful to all the officers and staff of Ltd Badarpur for extending helping hand whenever needed . NTPC ., a Furthermore, I seek extreme pleasure in expressing my feelings of indebtedness to Mr Rakesh Gupta, Mr Prempal, Mr R.S.Dabar, Mr Mukesh Kumar and Mr Chetan Singh for their guidance during the training.
ASHISH KUMAR SWAMI ELECTONICS AND COMMUNICATION ENGINEERING ABES INSTITUTE OF TECHNOLOGY, GHAZIABAD
IN T R O D U C T IO N
NTPC is the largest power generation company in India, with comprehensive in-house capabilities in building and operating power projects. It is producing 31,704MW (INCLUDEING 2864MW UNDER JVs. With a current generating capacity of 31134 MW, NTPC has embarked on plans to become a 75,000 MW company by 2017. It was founded on November 7, 1975.Its family consists of 18 coal based power plant producing (23209 MW) and 8 gas based power plant having a capacity of (5435 mw). It is also setting up a hydro based power plants having capacity 2471MW. It is one of the largest Indian companies with a market cap of of more than US$50 BILLION and has total assets of around US$ 20 BILLION. In this firm government has 89.5% stake and 10.5% with public. NTPC is ranked 463rd biggest company in the world, 5th biggest Indian company and 2nd largest Asian power generator. It produces 26350MW which is 20.18% the total 130,539MW of of all India consumption. More than one-fourth of Indias generation with one-fifth capacity. The next largest power utility owns 7.9% of market share in terms of capacity and 8.12% of share in terms of units generated. NTPCs vision is to become world classintegrated power major, powering Indias growth, with increasing global presence. It also develops and provides reliable power, related products and services at competitive prices, integrating multiple energy sources with innovative and eco-friendly technologies andcontributes to society. This firm is also well concern about the environmental factors.NTPC has set new benchmarks for the power industry both in the area of power plant construction and operations. Its providing power at the cheapest average tariff in the country.NTPC is committed to the environment, generating power at minimal environmental cost and preserving the ecology in the vicinity of the plants. NTPC has undertaken massive a forestation in the vicinity of its plants. Plantations have increased forest area and reduced barren land. The massive a forestation by NTPC in and around its Ramagundam Power station (2600 MW) have contributed reducing the temperature in the areas by about 3c. NTPC has also taken proactive steps for ash utilization. In 1991, it set up Ash Utilization Division. A "Centre for Power Efficiency and Environment Protection (CENPEEP)" has been established in NTPC with the assistance of United States Agency for International Development. (USAID). Cenpeep is efficiency oriented, eco-friendly and eco-nurturing initiative - a symbol of NTPC's concern towards environmental protection and continued commitment to sustainable power development in India. As a responsible corporate citizen, NTPC is making constant efforts to improve the socio-economic status of the people affected by its projects. Through its Rehabilitation and Resettlement programmes, the company endeavors to improve the overall socio economic status Project Affected Persons. NTPC was among the first Public Sector Enterprises to enter into a Memorandum of Understanding (MOU) with the Government in 1987-88. NTPC has been placed under the 'Excellent category' (the best category) every year since the MOU system became operative .Harmony between man and environment is the essence of healthy life and growth. Therefore, maintenance of ecological balance and a pristine environment has been of utmost importance to NTPC. It has been taking various measures discussed below for mitigation of environment pollution due to power generation .Environment Policy & Environment Management System Driven by its commitment for sustainable growth of power, NTPC has evolved a well defined environment management policy and sound environment practices for minimizing environmental impact arising out of setting up of power plants and preserving the natural ecology. National Environment Policy: At the national level, the Ministry of Environment and Forests had prepared a draft Environment Policy (NEP) and the Ministry of Power along with NTPC actively participated in the deliberations of the draft NEP. The NEP 2006 has since been approved by the Union Cabinet in May 2006. NTPC Environment Policy: As early as in November 1995, NTPC brought out a comprehensive document entitled "NTPC Environment Policy and Environment Management System". Amongst the guiding principles adopted in the document are company's proactive approach to environment, optimum utilization of equipment, adoption of latest technologies and continual
environment improvement. The policy also envisages efficient utilization of resources, thereby minimizing waste, maximizing ash utilization and providing green belt all around the plant for maintaining ecological balance. Environment Management, Occupational Health and Safety Systems: NTPC has actively gone for adoption of best international practices on environment, occupational health and safety areas. The organization has pursued the Environmental Management System (EMS) ISO 14001 and the Occupational Health and Safety Assessment System OHSAS 18001 at its different establishments. As a result of pursuing these practices, all NTPC power stations have been certified for ISO 14001 & OHSAS 18001 by reputed national and international Certifying Agencies. Pollution Control systems: While deciding the appropriate technology for its projects, NTPC integrates many environmental provisions into the plant design. In order to ensure that NTPC comply with all the stipulated environment norms, various state-of-the-art pollution control systems / devices as discussed below have been installed to control air and water pollution. Electrostatic Precipitators: The ash left behind after combustion of coal is arrested in high efficiency Electrostatic Precipitators (ESPs) and particulate emission is controlled well within the stipulated norms. The ash collected in the ESPs is disposed to Ash Ponds in slurry form. Flue Gas Stacks: Tall Flue Gas Stacks have been provided for wide dispersion of the gaseous emissions (SOX, NOX etc) into the atmosphere. Low-NOX Burners: In gas based NTPC power stations, NOX emissions are controlled by provision of Low-NOX Burners (dry or wet type) and in coal fired stations, by adopting best combustion practices. Neutralization Pits: Neutralization pits have been provided in the Water Treatment Plant (WTP) for pH correction of the effluents before discharge into Effluent Treatment Plant (ETP) for further treatment and use. Coal Settling Pits / Oil Settling Pits : In these Pits, coal dust and oil are removed from the effluents emanating from the Coal Handling Plant (CHP), coal yard and Fuel Oil Handling areas before discharge into ETP.DE & DS Systems: Dust Extraction (DE) and Dust Suppression (DS) systems have been installed in all coal fired power stations in NTPC to contain and extract the fugitive dust released in the Coal Handling Plant (CHP). Cooling Towers :Cooling Towers have been provided for cooling the hot Condenser cooling water in closed cycle Condenser Cooling Water (CCW) Systems. This helps in reduction in thermal pollution and conservation of fresh water .Ash Dykes & Ash Disposal systems : Ash ponds have been provided at all coal based stations except Dadri where Dry Ash Disposal System has been provided. Ash Ponds have been divided into lagoons and provided with garlanding arrangements for change over of the ash slurry feed points for even filling of the pond and for effective settlement of the ash particles . Ash in slurry form is discharged into the lagoons where ash particles get settled from the slurry and clear effluent water is discharged from the ash pond. The discharged effluents conform to standards specified by CPCB and the same is regularly monitored. At its Dadri Power Station, NTPC has set up a unique system for dry ash collection and disposal facility with Ash Mound formation. This has been envisaged for the first time in Asia which has resulted in progressive development of green belt besides far less requirement of land and less water requirement as compared to the wet ash disposal system.Ash Water Recycling System: Further, in a number of NTPC stations, as a proactive measure, Ash Water Recycling System (AWRS) has been provided. In the AWRS, the effluent from ash pond is circulated back to the station for further ash sluicing to the ash pond. This helps in savings of fresh water requirements for transportation of ash from the plant. The ash water recycling system has already been installed and is in operation at Ramagundam, Simhadri, Rihand, Talcher Kaniha, Talcher Thermal, Kahalgaon, Korba and Vindhyachal. The scheme has helped stations to save usage quantity of fresh water required a smake- aterforisposalofash. Dry Ash Extraction System(DAES): Dry ash has much higher utilization potential in ash-based products (such as bricks,
aerated autoclaved concrete blocks, concrete, Portland pozzolana cement, etc.). DAES has been installed at Unchahar, Dadri, Simhadri, Ramagundam, Singrauli, Kahalgaon, Farakka, Talcher Thermal,Korba, Vindhyachal, TalcherKanihaand BTPS.Liquid Waste Treatment Plants&Management System: The objective of industrial liquid effluent treatment plant (ETP) is to discharge lesser and cleaner effluent from the power plants to meet environmental regulations. After primary treatment at the source of their generation, the effluents are sent to the ETP for further treatment. The composite liquid effluent treatment plant has been designed to treat all liquid effluents which originate within the power station e.g. Water Treatment Plant (WTP), Condensate Polishing Unit (CPU) effluent, Coal Handling Plant (CHP) effluent, floor washings, service water drains etc. The scheme involves collection of various effluents and their appropriate treatment centrally and re-circulation of the treated effluent for various plant uses.NTPC has implemented such systems in a number of its power stations such as Ramagundam, Simhadri, Kayamkulam, Singrauli, Rihand, Vindhyachal, Korba, Jhanor Gandhar, Faridabad, Farakka, Kahalgaon and Talcher Kaniha. These plants have helped to control quality and quantity of the effluents discharged from the stations. Sewage Treatment Plants & Facilities: Sewage Treatment Plants (STPs) sewage treatment facilities have been provided at all NTPC stations to take care of Sewage Effluent from Plant and township areas. In a number of NTPC projects modern type STPs with Clarifloculators, Mechanical Agitators, sludge drying beds, Gas Collection Chambers etc have been provided to improve the effluent quality. The effluent quality is monitored regularly and treated effluent conforming to the prescribed limit is discharged from the station. At several stations, treated effluents of STPs are being used for horticulture purpose. Environmental Institutional Set-up: Realizing the importance of protection of the environment with speedy development of the power sector, the company has constituted different groups at project, regional and Corporate Centre level to carry out specific environment related functions. The Environment Management Group, Ash Utilisation Group and Centre for Power Efficiency & Environment Protection (CENPEEP) function from the Corporate Centre and initiate measures to mitigate the impact of power project implementation on the environment and preserve ecology in the vicinity of the projects. Environment Management and Ash Utilization Groups established at each station, look after various environmental issues of the individual station. Environment Reviews: To maintain constant vigil on environmental compliance, Environmental Reviews are carried out at all operating stations and remedial measures have been taken wherever necessary. As a feedback and follow-up of these Environmental Reviews, a number of retrofit and up-gradation measures have been undertaken at different stations. Such periodic Environmental Reviews and extensive monitoring of the facilities carried out at all stations have helped in compliance with the environmental norms and timely renewal of the Air and Water Consents. Up gradation & retro fitting of Pollution Control Systems: Waste Management Various types of wastes such as Municipal or domestic wastes, hazardous wastes, Bio-Medical wastes get generated in power plant areas, plant hospital and the townships of projects. The wastes generated are a number of solid and hazardous wastes like used oils & waste oils, grease, lead acid batteries, other lead bearing wastes (such as garkets etc.), oil & clarifier sludge, used resin, used photo-chemicals, asbestos packing, e-waste, metal scrap, C&I wastes, electricial scrap, empty cylinders (refillable), paper, rubber products, canteen (bio-degradable) wastes, buidling material wastes, silica gel, glass wool, fused lamps & tubes, fire resistant fluids etc. These wastes fall either under hazardous wastes category or non-hazardous wastes category as per classification given in Government of Indias notification on Hazardous Wastes (Management and Handling) Rules 1989 (as amended on 06.01.2000 & 20.05.2003). Handling and management of these wastes in NTPC stations have been discussed below. Advanced / Eco-friendly Technologies NTPC has gained expertise in operation and management of 200 MW and 500 MW Units installed at different Stations all over the country and is looking ahead for higher capacity Unit sizes with super critical steam
parameters for higher efficiencies and for associated environmental gains. At Sipat, higher capacity Units of size of 660 MW and advanced Steam Generators employing super critical steam parameters have already been implemented as a green field project. Higher efficiency Combined Cycle Gas Power Plants are already under operation at all gas-based power projects in NTPC. Advanced clean coal technologies such as Integrated Gasification Combined Cycle (IGCC) have higher efficiencies of the order of 45% as compared to about 38% for conventional plants. NTPC has initiated a techno-economic study under USDOE / USAID for setting up a commercial scale demonstration power plant by using IGCC technology. These plants can use low-grade coals and have higher efficiency as compared to conventional plants. With the massive expansion of power generation, there is also growing awareness among all concerned to keep the pollution under control and preserve the health and quality of the natural environment in the vicinity of the power stations. NTPC is committed to provide affordable and sustainable power in increasingly larger quantity. NTPC is conscious of its role in the national endeavour of mitigating energy poverty, heralding economic prosperity and thereby contributing towards Indias emergence as a major global economy. Lay out of Employees
1.
Cooling towers
Cooling 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.
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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.
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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.
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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.
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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. Pulverizer A pulverizer is a device for grinding coal for combustion in a furnace in a fossil fuel power plant. 9. Boiler Steam Drum Steam 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 mud- drum /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.
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 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.
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.
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. 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.
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 Steam
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 waterquenched 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
TABLES OF CYCLES
COAL CYCLE
CONDENSATE CYCLE
STEAM CYCLE
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- Its 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- Its 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
Miniature Circuit Breaker- They are used with combination of the control circuits to. a) Enable the taring of plant and distributors. b) Protect the circuit in case of a fault. In consists of current carrying ontacts, one movable and other fixed. When a fault occurs the contacts separate and are is stuck between them. There are three types of trips viz. Annual trip, Thermal trip and 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 KVA .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).
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.
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: Signal condition in grand transmission Modulating controls
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 heardt of Instrumentation .
Pressure Electricity HL switch Start Level low Pressure in line Level High LL switch pump Stop Pressure AND
High level OR
Electricity
Electricity
TEMPERATURE MONITORING
We can use Thernocouples or RTDs for temperature monitoring Normally RTDs are used for low temperatures. Thermocoupkle 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. We pass a constant curre t 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 ) 1000
Pt1000 : 0 0C -
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 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. 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
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) 2. Motorized valves (actuator) - works on motor action 3. Pneumatic valve (actuator) _ works due to pressure of compressed air 4. Hydraulic valve