GENERATION AND CONTROL OF POWER AT NTPC FARIDABAD

An Industrial Training Report By

Mandeep Malik (Roll-08ME340)

ITM University, Sector 23A, Gurgaon-122017

Under guidance of

Sh. R.K.Niranjan Manager(HR-EDC)

NTPC FARIDABAD
(Village Mujedi,P.O. Neemka,Dist. Faridabad,Haryana)

INDEX
CONTENT PAGE NO.

1. About the company a. Evolution of NTPC b. NTPC group c. Installed Capacity d. NTPC Strategies e. NTPC Faridabad f. International Cell g. NTPC Operations 2. Gas to Electricity Conversion
3. Automation and Control

10 23

a. Control and Monitoring Mechanisms b. Pressure Control c. Temperature Control d. Flow Control e. Control Valves

ACKNOWLEDGEMENTS

Its my pleasure to thank various people who directly or indirectly contributed in the develpoement of this report and who influenced my thinking, behavior, acts during my training period.

I express my sincere gratitude towards ITM UNIVERSITY for providing me an opportunity to undergo summer training at NTPC FARIDABAD.

I am thankful to Mr. R.K Niranjan Sir for accepting me as a summer trainee in NTPC.

I also extend my sincere appreciation to Sr. Manager Amit Singh For his valuable suggestions and precious time in accomplishing my project report.

Finally, I would like to thank the almighty and my parents for their moral support and my friends with whom I shared my day to day experience and received a lots of suggestions that improved my quality of work.

Mandeep Malik 08ME340

ABOUT THE COMPANY

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). NTPC acquired 50% equity of the SAIL Power Supply Corporation Ltd. (SPSCL). This JV company operates the captive power plants of Durgapur (120 MW), Rourkela (120 MW) and Bhilai (74 MW). NTPC also has 28.33% stake in Ratnagiri Gas & Power Private Limited (RGPPL) a joint venture company between NTPC, GAIL, Indian Financial Institutions and

Maharashtra SEB Holding Co. Ltd.NTPCs share on 31 Mar 2007 in the total installed capacity of the country was 20.18% and it contributed 28.50% of the total power generation of the country during 2006-07.

EVOLUTION OF NTPC

1975

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.

1997

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.

NTPC became a listed company with majority Government ownership

2004

of 89.5%. NTPC becomes third largest by Market Capitalisation of listed companies

2005

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.

2010

Forbes Global 2000 for 2010 ranked it 341th[3] in the world

NTPC GROUP

NTPC Limited
Subsidiaries

NTPC Vidyut Vyapar Nigam Limited 100%

NTPC Electric Supply Co. Limited 100%

Pipavav Power Development Co. Ltd 100%

NTPC Hydro Limited 100%

Joint Ventures

NTPC-SAIL Power Company Pvt. Limited 50% NTPC-SAIL Power Company Pvt. Limited 50

Bhilai Electric Supply Co. Pvt. Limited 50%

NTPC Alstom Power Services Pvt. Limited 50%

Utility Powertech Limited 50%

NTPC Tamilnadu Energy Co. Limited 50%

PTC India Limited 8%

Ratnagiri Gas & Power Private Ltd 28.33%

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.

Pursuing Business Opportunities in: Sri Lanka Saudi Arabia UAE Iran Jordan Bahrain Egypt Malaysia Indonesia Vietnam Thailand Sudan Nigeria Yemen

NTPC OPERATIONS
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 PLF 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.

It may be seen from the table below that while the installed capacity has increased by 56.40% in the last nine years, the employee strength went up by only 3.34%

Description Installed Capacity Generation No. of employees Generation/employee

Unit MW MUs No. MUs

199798 16,847 97,609 23,585 4.14

2006-07 26,350 1,88,674 24,375 7.74

% of increase 56.40 93.29 3.34 86.95

ECOLOGICAL MONITORING PROGRAMME

NTPC has undertaken a comprehensive Ecological Monitoring Programme through Satellite Imagery Studies covering an area of about 25 Kms 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.

10

LINE DIAGRAM SHOWING GAS TO ELECTRICITY CONVERSION AT FARIDABAD GAS POWER PLANT

NTPC Faridabad has Two Gas Turbines manufactured by Seimens and One Steam Turbine from BHEL

11

COMBINED CYCLE In combined/closed cycle, two combustion turbine-generators operate in conjunction with two heat-recovery steam generators and a steam turbine-generator. In the first cycle, fuel is burned and the resulting combustion gases power two turbine-generators to produce electricity. Hot exhaust normally lost during this process is captured and routed through the two heat-recovery steam generators. These units boil water to create steam, which spins an additional turbinegenerator and produces more electricity. Finally, the steam is discharged into a condenser, which returns the steam to its liquid state for recycling.

At FGPS, the gas turbines installed are based on the Brayton Cycle while the steam turbine is based on Rankine Cycle. These cycles are explained below. BRAYTON CYCLE Gas turbines operate on this cycle. In this cycle air is compressed in a compressor. This compressed air is used for combustion and the combustion product is allowed to expand in the turbine, which is coupled with the generator. In modern gas turbines the temperature of the exhaust gases is in the range 500C to 580C.

12

RANKINE CYCLE The conversion of heat energy to mechanical energy with the aid of steam is carried out through this cycle, which involves: The initial state of the working fluid is water, which at certain temperature is compressed by the pump and fed to the boiler. In the boiler the compressed water is heated at constant pressure. Superheated steam is expanded in the turbine which is coupled with the generator.

COMBINING TWO CYCLES TO IMPROVE EFFICIENCY We have seen in the above two cycles that the gas turbine exhaust is of 500C-580C and in the Rankine cycle temperature required to generate is 500C-560C. So we use the gas turbine exhaust to generate steam in the Rankine cycle and save fuel required to heat the water.

ADVANTAGE OF THE COMBINED CYCLE PLANTS Apart from the higher efficiency, the combined cycle power plants have following advantages: Low installation cost Low gestation period Better reliability Low environmental pollution

If efficiency of gas turbine cycle (where natural gas is used as fuel) is 31% (which is usually the case) and the efficiency of Rankine cycle is 35%, then over all efficiency comes to 49%.

Overview of the power plant Plant overview presents a broad picture on how the fuel is utilized to generate power without going much in detail. It shows how the different units of a power plant work in tandem to form a complex but highly organized system, which is efficient and very reliable.

13

Gas turbine system

The gas turbine is a common form of heat engine working with a series of processes consisting of compression of air taken from atmosphere, increase of working medium temperature by constant pressure ignition of fuel in combustion chamber, expansion of SI and Internal Combustion (IC) engines in working medium and combustion, but it is like steam turbine in its aspect of the steady flow of the working medium.

For the gas turbine to produce any work, the hot gases must expand from a high pressure to a low pressure. Therefore the gases must first be compressed. If after the compression the fluid were expanded through the turbine, the power produced would equal that used by the compressor, provided that both the turbine and compressor functioned ideally.

14

If heat were added to the fluid before it reached turbine, raising its temperature, then an increase in power output could be achieved. If more and more thermal energy could be added to the fluid then more and more power output could be produced. Unfortunately this cannot occur as the turbine blades have metallurgical thermal limit. If the gases continuously enter at a temperature higher than this, the combined thermal and material stresses in the blades will cause them to fail. Typically, inlet temperature of 1300K may be found in industrial turbines and inlet temperatures in experimental models are up to 1500K. At P.P.C.L two gas turbines, Model 9E of make General Electric (GT1) and Bharat Heavy Electrical Ltd. (GT2) are being used. The 9E is a simple flow cycle, single shaft gas turbine with fourteen reverse-flow combustion systems. The 9E assembly consists of six major section or groups: 1. 2. 3. 4. 5. 6. Air inlet. Compressor. Combustion system. Turbine. Exhaust. Support systems.

1. GAS PATH DESCRIPTION When the turbine starting system is actuated and the clutch is engaged, ambient air is drawn through air inlet plenum assembly, which is then filtered & compressed in the 17-stage, axial flow compressor. Then this compressed air from compressor flow into the annular space surrounding the 14-combustion chambers. From there, it flows into the combustion liners for proper fuel combustion.

Fuel for combustion is being supplied by Gail (Gas Authority of India Ltd.) through HBJ (Hazirapur-Bijapur-Jagdishpur) gas line at a pressure of 24Kg at 26oC.

This fuel is filtered for the removal of solid particles at the Gas Conditioning Skid before being fed into 14 equal flow lines each terminating at a fuel nozzle centered in the end plate of a separate combustion chamber. Prior to being distributed to the nozzles the fuel is accurately controlled to provide an equal flow into the 14 nozzle feed lines at a rate

15

consistent with the speed and the load requirements of the gas turbine. The nozzle introduces the fuel into the combustion chamber where it is mixed with the combustion air. This fuel air mixture is then ignited in one of the 14-chambers and the flame thus produced is propagated to ignite other fuel chambers through connecting cross-fire tubes. After the turbine rotor approximates operating speed, combustion chamber pressure causes the spark plugs to retract so as to remove their electrodes from the hot flame zone. The hot gasses from the combustion chambers expand into 14 separate transition pieces attached to the aft end of the combustion chamber liners & flow from there to three-stage Turbine Section. Each stage consists of a row of fixed nozzles followed by a row of routable turbine buckets. In each nozzle row, the kinetic energy of the jet increases while the pressure drops & each following row of moving buckets, a portion of kinetic energy of jet turns the turbine rotor. Since the turbine is coupled to the generator rotor, the resulting rotation of turbine is transferred to generator, which generates the electrical power. After passing the third stage buckets, the exhaust gasses (at about 570oC) are directed to the HRSG before being directed into exhaust hood (at about 140oC). The exhaust hood contains a series of turning vanes to turn the gasses from an axial direction to radial direction to minimize the exhaust hood losses. The gasses are then passed into the exhaust plenum & are expelled into atmosphere through the exhaust stack.

Heat recovery steam generator The Heat Recovery Steam Generator (HRSG) is installed so as to increase the overall efficiency of the plant. It works by using the utilizing flue gases of the gas turbine instead of burning fuel to produce steam which runs a steam turbine which has a generator coupled with it to produce electric power. With HRSG, the efficiency of the plant may be in excess of 48%.

The HRSG, installed at FGPS, is a horizontal, natural circulation, single drum, dual pressure, unfired, water-tube boiler. It is designed to generate steam quantities 190 T/hr for the HP drum and 40 T/hr for the LP drum. The feed water temperature is approximately 275 degree Celsius for the HP drum while for the LP drum, it is, 150.1 C at the designed point.

16

The gas turbine flue gases act as the heat source of the boiler. The combustion products heat water in a boiler where it is converted to steam. This steam drives the steam turbine, which is mechanically coupled, to a generator. The modern large sized boilers are of water-tube type design. In these boilers, water flows inside the tubes and the hot flue gases flow outside of them. The circulation of water through the tubes of the boiler is forced circulation through the action of pumps. Flue gas flow Flue gases from the exhaust of the Gas turbine are at the temperature of 540 degree Celsius and are generally at very high velocity . therefore the fluegases are passed through a diffuser where pressure increases at the expanse of the velocity. Next the flue gases are allowed to pass through diverter damper gates which permit the flow of gases out of the bypass chimney or towards the HRSG depending upon the position of the gate. The flue gases then rise along the height of the HRSG and are evenly distributed using mechanical barriers like gas distribution screens for the horizontal flow of the flue gases along the HRSG. The flue gases generally carry smoke which deposit on the water tube as soot and reduce the heat transfer and hence HRSG is provided with soot blowers namely FRSB full retractable soot blowers and HRSBs as per requirements.

Salient Features and Operation The boiler is divided into nine zones. In order of higher temperature, they are as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. HP Super heater-II HP Super heater HP Evaporator HP Economizer II LP Super heater LP Evaporator HP Economizer I LP economiser Condensate preheater (CPH)

17

Feedwater at BFP discharge is then pumped separately via HP BFP and LP BFP to the High Pressure (HP) and Low Pressure (LP) drums from which HP and LP steam is derived respectively. The cycle for both the HP and LP steam is basically the same. The water is first taken to the respective economizers to heat the water and then taken to the evaporator where the water is converted to steam. This steam is further heated to produce superheated steam. This process takes place in the respective super heaters. Now, there is a possibility that the temperature of the HP steam becomes very high (more than the specifications) as there are two super heaters. To prevent the steam from attaining very high temperatures, a device called DeSuper heater is installed between the two super heaters. It works by sprinkling water on the steam as the steam passes through it. This lowers down the temperature but also wets the steam. The steam is dried in the next superheated and hence the temperature of the steam is controlled. De-superheated is used only when required and the amount of water sprinkled is also controlled so as not to decrease the temperature of the steam too low that the second superheated cannot increase it to the optimum limit. This superheated steam is then taken to the turbine where it is allowed to expand and cool and do mechanical work on the turbine rotor. The expanded steam

18

from the HP steam still has sufficient amount of heat and is taken to the LP turbine. The steam from the LP turbine is taken to the Condenser where it is converted back to water, as we cannot pump steam. The water is extracted from the condenser by the Condensate Extraction Pump (CEP). The water is extracted from the condenser as there is low pressure (vacuum, maintained by vacuum pumps) inside the condenser which has to be maintained otherwise there is a risk of back-flow of steam back to the turbine. So the difference in pressure has to be maintained and water has to be forced out. A part of the steam is also tapped to seal the turbine, which is cooled in the Gland Steam Cooler (GSC). The sealing is very critical as the difference in pressure is quite large between that inside the turbine and the outside. The steam has the tendency to escape and to prevent that we require the sealing. The water from the condenser and GSC is pumped together back to the condensate pre-heater and the cycle begins again. Everything in the plant works on a closed cycle to increase efficiency and maintain economical production. The de-mineralized water is produced after a long process involving dozing, filtering, reverse osmosis, ion exchangers, etc. which makes the water purification expensive. So, this water is not wasted and re-used. Only a small amount of make-up water is taken from the plant. The condensing water (from LSP) in the condenser is cooled again and re-used to condense steam to water in the condenser.

19

Steam turbine system The turbine is a tandem compound machine with High Pressure (HP) and Low Pressure (LP) sections. The HP section is a stage flow turbine whereas the LP section is a double flow. Rigid couplings connect the individual turbine rotors and generator rotor. The HP turbine has been constructed for throttle control governing. The initial steam is admitted before the blading by two combined main steam stop and control valves. The steam from HP turbine exhaust is led to the LP turbine through cross-around pipes. Additional steam from LP stage of waste heat recovery steam generator is passed to the LP turbine via two-combined LP stops and control valves.

20

HIGH PRESSURE (HP) TURBINE The HP turbine is of single flow, double shell, construction with horizontally split casing. Allowance is made for thermal movement of the inner casing within the outer casing. The main steam enters the inner casing from top and bottom. The provision of an inner casing confines high steam inlet temperature and pressure conditions to the admission section of this casing, while the joint flange of the outer casing is subjected only to the lower pressure and temperature effective at the exhaust from the inner casing.

LOW PRESSURE (LP) TURBINE The casing of the double flow LP turbine is of three-shell design. The shells are of horizontally split-welded construction. The inner casing, which carries the first rows of stationary blades, is supported on the inner-outer casing so as to allow for thermal expansion. The inner-outer casing rests at four points on longitudinal girders, independent of the outer casing. Three guide blade carriers, carrying the last guide blade rows are bolted to the inner-outer casing.

BLADING The entire turbine is provided with reaction blading. The moving blades of the HP turbine and the initial rows of the LP turbine with inverted T-roots and integral shrouding are machined from solid rectangular bars. The last stages of the LP turbine consist of twisted, drop forged moving blades with fir-tree roots inserted in corresponding grooves of rotor. Like the moving blades, the HP stationary blades of HP turbine and the front rows of LP turbine are designed with integrally milled inverted T-roots and shrouds. The last stages of LP turbine have guide blade rows of fabricated construction.

Condensate Steam after the extraction of work in the hp and lp turbines goes to condenser through flash box where the LP drain enters the condenser. Cooling water is supplied by the CW tubes where the water is pumped in by CW pumps. Water generally gets heated by 7-8 degree celcius . steam from the LP exhaust gets condensed via indirect heating and is collected below in the HOTWELL. Very low pressure in the condenser is maintained by vacuum pumps. To make up for the water losses during the steam cycle , make up water is added to the condenser via DM

21

water line. This DM water can be taken directly from the DM water line or through the Reserve Feed Tank . Water from the Hotwell is extracted by condensate extraction pumps(CEP). In this module two CEPs are provided while only one is operated while other is kept in standby mode. Water from the CEP discharge enters the Gland steam condenser(GSC) where it is heated by the gland steam via indirect heating. Gland steam condenses and is discharged back into the condenser. Heated water from the GSC is then taken to LPH and other feedwater systems. Condenser also receives the HP and LP bypass lanes from the turbines . The powerplant chemistry is constantly monitored via the specific conductivity and the PH level of the water in the condenser. Hotwell level is also important and is constantly controlled.

Cooling water system The water in the coolant tubes of the condenser gets heated and is then taken to the cooling towers. Here the water gets sprinkled from the top of the specially designed cooling tower where the rising air from the bottom cools the water close to its wet bulb temperature. Thus temperature is lowered by 7-8 degree celcius. Unsaturated air of low relative humidity gets saturated in this process and leaves the cooling tower from the top. The suction of the air is

22

provided by the induced draft fans provided at the tower top. Thus cooling tower is based on the forced draft cooling. Hence the height of the tower is quite low. Cooled water is discharged into the sump where the make up water is added as water loss occurs during the cooling through evaporation. Cooling water pumps get the suction from the sump and pump the water towards the condenser.

Feed water system LP heater Feed water from the GSC enters the LPH where the bled steam heats the feed water by indirect heating .LPH bypass lane is also provided to bypass the LP heater . CPH and CPH RCP The water from the LP heater goes to condensate preheater kept at the near exhaust of the HRSG. The flue gases before being discharged to the atmosphere are used to heat the feedwater. In this process the temperature of the flue gases falls down from 160 to 104 degree celcius. Generally this is above the saturation temperature of the SOX and the NOX gases in the chimney exhaust. When the natural gas is used the temperature is quite high and saturation temperature llimit is not reached however if the naptha is used then the flue gas temperature is lower by around 10 degree celcius hence the NOX gases could condense and form acidic products leading to cold end corrosion, if the CPH is used. Hence to overcome this recirculation pumps(RCPs) are switched on which pump the hot water at CPH discharge back to the CPH inlet thus considerably reducing the heat transfer and hence the flue gas temperature doesnt reduce to the saturation temperature limit. Deaerator Water from the CPH heater enters the the deaerator where the dissolved gases are removed from it. The steam from the LP superheater enters the deaerator from the bottom while the feedwater is sprinkled fron the top. The rising steam comes in direct contact of water thereby heating the water and the dissolved gases which as a result escape from the top along with some of the steam. The condence steam and the water are collected below in the storage tank.

23

24

AUTOMATION AND CONTROL SYSTEM

AUTOMATION: THE DEFINITION

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 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.

25

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. Figures 1 shows the sequence of a rapid restart using automation for a typical coal-fired station. Even a well- trained 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. Prevent sub-process and process tripping chain reaction following a process component trip.

26

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 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

27

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.

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 process-oriented lines. In other words, the control system structure should map on to the hierarchy process structure. BHELs PROCONTROL P, a microprocessor based intelligent remote multiplexing system, meets this requirement completely.

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

28

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

29

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

30

Transmitter types use transducers (electrical to electrical normally) they are used where continuous monitoring is required Normally capacitive transducers are used

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 %

31

The whole system used is SCADA based

ANALOG INPUT

MICRO PROCESSOR

INPUT

4-20 mA

MODULE

ALARM

We use DDCMIC control for this process. Programmable Logic Circuits ( PLCs) are used in the process as they are the heardt of Instrumentation .

Pressure
HL switch

Electricity Level low

AND Start

Pressure in line
LL switch

Level High

High level pump Electricity Pressure

OR

Stop

Electricity

32

BASIC PRESSURE CONTROL MECHANISM

Hence PLC selection depends upon the Criticality of the Process

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 )

33

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.

34

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.

35

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.

36

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

37

REFERENCES En.wikipedia.org www.ntpc.co.in www.google.com