DEPARTMENT OF ELECTRONICS AND COMMUNICATION

JAYPEE INSTITUTE OF INFORMATION TECHNOLOGY, NOIDA

Industrial Training Report Submission

ON

Introduction To Power Plant

Submitted By :

Venu Vedant (13102406)

Evaluated By : Ms. Garima Kapur

Supervised By : Mr. A.K Pramanik (AGM C&I)

Start Date of Training : 08-Jul-2016

End Date of Training : 04-Aug-2016

Sr.No. TITLE PAGE No.

2. Declaration 4

3. Overview 5

4. Introduction to Components 7

5. Table of Cycles 14

6. Control & Instrumentation 16

7. Automation & Control 17

8. System Overview 18

9. Temperature Monitoring 19

10. Analysis 20

11. References 21
ACKNOWLEDGEMENT

I am highly indebted to AGM of Control and Instrumentation Department Mr. A.K

Pramanik, and all members of department for providing me an opportunity to have practical

exposure at NTPC Ltd. Dadri .I express my sincere thanks to Ms. Garima Kapur for

evaluating my project.

Signature of the student ..

Name of Student VENU VEDANT (13102406)

Date ..
DECLARATION

I hereby declare that the project work entitled Introduction To Power Plant submitted to the

Ms. Garima Kapur is a record of an original work done by me under the guidance of Mr. A.K

Pramanik, AGM (Control and Instrumentation Department) and this project work is submitted

in the partial fulfillment of the requirements for the award of the degree of Bachelor of

Technology in Electronics and Communication Engineering. The results embodied in this

report has not been submitted to any other University or Institute for the award of any degree.
OVERVIEW

NTPC Limited is the largest thermal power generating company of India, 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.

CORPORATE VISION:

To be the worlds largest and best power producer, powering Indias growth

CORE VALUES:

B- Business ethics

C-Customer focus

O-Organizational & professional pride

M-Mutual respect & trust

I-Innovation & speed

T-Total quality for excellence

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 components of a coal power thermal power

station-

Cooling water pump

Three phase transmission line

Step up transformer

Electrical generator

Low pressure steam

Boiler feed water pump

Surface condenser

Intermediate pressure steam turbine

Steam control valve

High pressure steam turbine

Deaerator feed water heater

Coal conveyer

Coal pulverizer

Boiler steam drum

Combustion air intake

Economiser

Airpreheater

Precipitator

Fuel gas stack

The description of some of the components above is as follows:

Cooling towers-

Cooling towers are evaporative coolers used for cooling water. Cooling towers use evaporation

of water to reject heat from processes such as cooling the circulating 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.

Three phase transmission line-

Three phase electric power is a common method of electric power transmission. It is a type of

polyphase system mainly used for power motors and many other devices. In a three phase

system, three circuits reach their instantaneous peak values at different times. Taking one

conductor as reference, the other two conductors are delayed in time by one-third and two-third
of cycle of the electrical current. This delay between phases has the effect of giving constant

power over each cycle of the current and also makes it impossible to produce a rotating magnetic

field in an electric motor. At the power station, an electric generator converts mechanical power

into a set of electric currents one from each electromagnetic coil or winding of the generator. The

currents are sinusoidal functions of time, all at the same frequency but offset in time to give

different phases. In a three phase system, the phases are spaced equally giving a phase separation

of one-third of one cycle. Generators output at a voltage that ranges from hundreds of volts to

30,000 volts. At the power station, Transformers step-up this voltage for suitable transmission.

After numerous further conversions in the transmission and distribution network, the power is

finally transformed to standard mains voltage i.e. the household voltage. The power may already

have been split into single phase at this point or it may be still three phase. The output of the

transformer is usually star connected with the standard mains voltage.

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.

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.

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.
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.

Feed Water Heater-

A feed water heater is a power plant component used to pre heat water delivered to a steam

generating boiler. Feed water heater improves the efficiency of the system. This reduces plant

operating costs and also helps to avoid thermal shock to boiler metal when the feed water is

introduced back into the steam cycle. Feed water heaters allow the feed water to be brought upto

the saturation temperature very gradually. This minimizes the inevitable irreversibility associated

with heat transfer to the working fluid(water). A belt conveyer consists of two pulleys, with a

continuous loop of material- the conveyer belt that rotates around them. The pulleys are

powered, moving the belt and the material on the belt forward. Conveyer belts are extensively

used to transport industrial and agricultural material, such as grain, coal, ores, etc.
Pulverizer-

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

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.

Turbines- A turbine is a turbomachine with at least one moving part called a rotor assembly,

which is a shaft or drum with blades attached. Moving fluid acts on the blades so that they move

and impart rotational energy to the rotor

Air Preheater-

Air preheater is a general term to describe any device designed to heat air before another process

(for example, combustion in a boiler). The purpose of the air preheater is to recover the heat

from the boiler flue gas which increases the thermal efficiency of the boiler by reducing the
useful heat lost in the fuel gas. As a consequence, the flue gases are also sent to the flue gas stack

(or chimney) at a lower temperature allowing simplified design of the ducting and the flue gas

stack. It also allows control over the temperature of gases leaving the stack.

Fuel gas stack-

A Fuel gas stack is a type of chimney, a vertical pipe, channel or similar structure through which

combustion product gases called fuel gases are exhausted to the outside air. Fuel gases are

produced when coal, oil, natural gas, wood or any other large combustion device. Fuel gas is

usually composed of carbon dioxide (CO2) and water vapor as well as nitrogen and excess

oxygen remaining from the intake combustion air. It also contains a small percentage of

pollutants such as particulates matter, carbon mono oxide, nitrogen oxides and sulfur oxides. The

flue gas stacks are often quite tall, up to 400 meters (1300 feet) or more, so as to disperse the

exhaust pollutants over a greater aria and thereby reduce the concentration of the pollutants to

the levels required by governmental environmental policies and regulations.

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.

Instrumentation can be well defined as a technology of using instruments to measure and control

the physical and chemical properties of a material.

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.
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
TEMPERATURE MONITORING

We can use Thernocouples or RTDs for temperature monitoring

Normally RTDs are used for low temperatures.

Thermocoupl1e 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 current through the RTD. So that if R changes then the Voltage also changes

RTDs used in Industries are Pt100 and Pt1000

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.
ANALYSIS

NTPC is the largest power company in India with an electric power generating capacity of 45,548

MW. Although the company has approx. 16% of the total national capacity it contributes to over 25%

of total power generation. NTPC Dadri is a unique power plant of NTPC group which has both coal

based thermal plant and gas based thermal plant of 1820 MW and 817 MW respectively and 5 MW

solar plant totaling 2642 MW.

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