Académique Documents
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Submitted by:
Ravi Jain
20085063
MNNIT ALLAHABAD
I would like to express a deep sense of gratitude and thanks to Mr AJEET KUMAR OJHA-DGM(HR)
without the wise counsel and able guidance, it would have been impossible to complete the report
in this manner.
The help rendered by Mrs RACHANA SINGH BHAL, Sr. Manager, National Thermal Power
Corporation for experimentation is greatly acknowledged.
I would also like to express gratitude to the HOD and other faculty members of department of
Electronics and communication engineering, MNNIT for their intellectual support throughout the
course of this work.
Finally, I would like to thanks Er. SONIA SINGH and all other technical staff of B.T.P.S. for giving
helping me throughout the training period.
Ravi Jain
ECE-MNNIT ALLAHABD
jainscoolravi@gmail.com
CONTENT
1. INTRODUCTION TO THE COMPANY
5. IT DEPARTMENT
6. REFERENCE
About The Company
Vision
Strategies
Environmental Policy
Evolution
About The Company
NTPC, the largest power Company in India, was setup in 1975 to accelerate power development in
the country. It is among the world’s largest and most efficient power generation companies. In
Forbes list of World’s 2000 Largest Companies for the year 2007, NTPC occupies 411th place.
NTPC has installed capacity of 29,394 MW. It has 15 coal based power stations (23,395 MW), 7 gas
based power stations (3,955 MW) and 4 power stations in Joint Ventures (1,794 MW). The
company has power generating facilities in all major regions of the country. It plans to be a 75,000
MW company by 2017.
NTPC has gone beyond the thermal power generation. It has diversified into hydro power, coal
mining, power equipment manufacturing, oil & gas exploration, power trading & distribution. NTPC
is now in the entire power value chain and is poised to become an Integrated Power Major.
NTPC's share on 31 Mar 2008 in the total installed capacity of the country was 19.1% and it
contributed 28.50% of the total power generation of the country during 2007-08. NTPC has
set new benchmarks for the power industry both in the area of power plant construction and
operations. With its experience and expertise in the power sector, NTPC is extending consultancy
services to various organizations in the power business. It provides consultancy in the area of
power plant constructions and power generation to companies in India and abroad.
In November 2004, NTPC came out with its Initial Public Offering (IPO) consisting of 5.25% as fresh
issue and 5.25% as offer for sale by Government of India. NTPC thus became a listed
company with Government holding 89.5% of the equity share capital and rest held by
Institutional Investors and Public. The issue was a resounding success. NTPC is among the
largest five companies in India in terms of market capitalization.
Growth Of NTPC Generation & PLF %
Recognizing its excellent performance and vast potential, Government of the India has identified
NTPC as one of the jewels of Public Sector 'Navratnas'- a potential global giant. Inspired by its
glorious past and vibrant present, NTPC is well on its way to realize its vision of being "A world class
integrated power major, powering India's growth, with increasing global presence".
VISION
Corporate vision: - “A world class integrated power major, powering India's growth
with increasing global presence.”
Mission :-Develop and provide reliable power related products and services at competitive prices,
integrating multiple energy resources with innovative & Eco-friendly technologies and contribution to the
society.
• Customer Focus
Sustainable
Development
Nuturing
Maintain
Human
sector
Resource
Leadership
STRATEGIES
Further
Technology Enchance
Initiatives Fuel Security
Exploit New
Business
Opportunities
Technological Initiatives
Introduction of steam generators (boilers) of the size of 800 MW.
Integrated Gasification Combined Cycle (IGCC) Technology.
Launch of Energy Technology Center -A new initiative for development of technologies with
focus on fundamental R&D.
The company sets aside up to 0.5% of the profits for R&D.
Roadmap developed for adopting ‘Clean Development.
Mechanism’ to help get / earn ‘Certified Emission Reduction.
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 3°c. 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- CENPEE" 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.
NTPC is the second largest owner of trees in the country after the Forest
department.
Electrostatic Precipitators:
The ash left behind after combustion of coal is arrested in high efficiency Electrostatic Precipitators
(ESP’s) and particulate emission is controlled well within the stipulated norms. The ash collected in
the ESP’s is disposed to Ash Ponds in slurry form.
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.
Neutralisation Pits:
Neutralisation 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.
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 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.
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 huge quantity of fresh water required as make-up water for disposal of
ash.
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.
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.
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 India’s 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.
EVOLUTION
BASIC PRINCIPLE
OPERATION OF BOILER
OPERATION OF TURBINE
INTRODUCTION
BADARPUR THERMAL POWER STATION was established on 1973 and it was the part of Central
Government. On 01/04/1978 is was given as No Loss No Profit Plant of NTPC.
Since then 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.
BASIC PRINCIPLE
As per FARADAY’s Law- “Whenever the amount of magnetic flux linked with a circuit changes, an EMF is
produced in the circuit. Generator works on the principle of producing electricity. To change the flux in the
generator turbine is moved in a great speed with steam.”
To produce steam, water is heated in the boilers by burning the coal. In a Badarpur Thermal Power
Station, steam is produced and used to spin a turbine that operates a generator. Water is heated,
turns into steam and spins a steam turbine which drives an electrical generator. After it passes
through the turbine, the steam is condensed in a condenser; this is known as a Rankine cycle.
Shown here is a diagram of a conventional thermal power plant, which uses coal, oil, or natural gas
as fuel to boil water to produce the steam. The electricity generated at the plant is sent to
consumers through high-voltage power lines The Badarpur Thermal Power Plant has Steam
Turbine-Driven Generators which has a collective capacity of 705MW. The fuel being used is Coal
which is supplied from the Jharia Coal Field in Jharkhand. Water supply is given from the Agra
Canal.
Electricity from Coal
There are basically three main units of a thermal power plant:
1. Steam Generator or Boiler
2. Steam Turbine
3. Electric Generator
Coupling
1. Cooling tower
8. Condenser
9. Intermediate pressure turbine
12. DE aerator
21. Re heater
23. Economiser
25. Precipitator
Low Pressure Turbine (LPT) consist of 4x2 stages. After passing through Intermediate Pressure
Turbine is is passed through LPT which is made up of two parts- LPC REAR & LPC FRONT. As
water gets cooler here it gathers into a HOTWELL placed in lower parts of Turbine.
8. Condenser
The steam coming out from the Low Pressure Turbine (a little above its boiling pump) is brought
into thermal contact with cold water (pumped in from the cooling tower) in the condenser, where it
condenses rapidly back into water, creating near
vacuum-like conditions inside the condenser chest.
In thermal plants, the primary purpose of surface condenser is to condense the exhaust steam from a
steam turbine to obtain maximum efficiency and also to convert the turbine exhaust steam into pure
water so that it may be reused in the steam generator or boiler as boiler feed water. By condensing
the exhaust steam of a turbine at a pressure below atmospheric pressure, the steam pressure drop
between the inlet and exhaust of the turbine is increased, which increases the amount heat available
for conversion to mechanical power. Most of the heat liberated due to condensation of the exhaust
steam is carried away by the cooling medium (water or air) used by the surface condenser.
Control valves are valves used within industrial plants and elsewhere to control operating conditions
such as temperature,pressure,flow,and liquid Level by fully 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
12. Deaerator
A Dearator is a device for air removal and used to remove dissolved gases (an alternate would be the
use of water treatment chemicals) from boiler feed water to make it non-corrosive. A dearator
typically includes a vertical domed deaeration section as the deaeration boiler 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 the heating surfaces giving rise to
localized heating and tube ruptures due to overheating. Under some conditions it may give to stress
corrosion cracking.
Deaerator level and pressure must be controlled by adjusting control valves- the level by regulating
condensate flow and the pressure by regulating steam flow. If operated properly, most deaerator
vendors will guarantee that oxygen in the deaerated water will not exceed 7 ppb by weight (0.005
cm3/L)
A Feed water heater is a power plant component used to pre-heat water delivered to a steam
generating boiler. Preheating the feed water reduces the irreversible involved in steam generation and
therefore improves the thermodynamic efficiency of the system.[4] This reduces plant operating
costs and also helps to avoid thermal shock to the boiler metal when the feed water is introduces
back into the steam cycle.
In a steam power (usually modelled as a modified Ranking cycle), feed water heaters allow the feed
water to be brought up to the saturation temperature very gradually. This minimizes the inevitable
irreversibility‟s associated with heat transfer to the working fluid (water). A belt conveyor consists of
two pulleys, with a continuous loop of material- the conveyor Belt – that rotates about them. The
pulleys are powered, moving the belt and the material on the belt forward. Conveyor belts are
extensively used to transport industrial and agricultural material, such as grain, coal, ores etc.
1. If our Coal has moisture content then it dries it so that a proper combustion takes place.
2. It raises the temperature of coal so that its temperature is more near to its Ignite Temperature so
that combustion is easy.
16. Pulverised Fuel Mill
A pulveriser is a device for grinding coal for combustion in a furnace in a fossil fuel power plant.
21. Reheater
Reheater are heaters which are used to raise the temperature of air which has been fallen down due to
various process.
23. Economizers
Economizer, or in the UK economizer, are mechanical devices intended to reduce energy
consumption, or to perform another useful function like preheating a fluid. The term economizer is
used for other purposes as well. Boiler, power plant, and heating, ventilating and air conditioning. In
boilers, economizer are heat exchange devices that heat fluids , usually water, up to but not normally
beyond the boiling point of the fluid. Economizers are so named because they can make use of the
enthalpy and improving the boiler‟s efficiency. They are a device fitted to a boiler which saves
energy by using the exhaust gases from the boiler to preheat the cold water used the fill it (the feed
water). Modern day boilers, such as those in cold fired power stations, are still fitted with
economizer which is decedents of Green‟s original design. In this context they are turbines before it
is pumped to the boilers. A common application of economizer is steam power plants is to capture
the waste hit from boiler stack gases (flue gas) and transfer thus it to the boiler feed water thus
lowering the needed energy input , in turn reducing the firing rates to accomplish the rated boiler
output . Economizer lower stack temperatures which may cause condensation of acidic combustion
gases and serious equipment corrosion damage if care is not taken in their design and material
selection.
25. Precipitator
An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that removes
particles from a flowing gas (such As air) using the force of an induced electrostatic charge.
Electrostatic precipitators are highly efficient filtration devices, and can easily remove fine
particulate matter such as dust and smoke from the air steam.
ESP‟s continue to be excellent devices for control of many industrial particulate emissions, including
smoke from electricity-generating utilities (coal and oil fired), salt cake collection from black liquor
boilers in pump mills, and catalyst collection from fluidized bed catalytic crackers from several
hundred thousand ACFM in the largest coal-fired boiler application.
The original parallel plate-Weighted wire design (described above) has evolved as more efficient (
and robust) discharge electrode designs were developed, today focusing on rigid discharge electrodes
to which many sharpened spikes are attached , maximizing corona production. Transformer –rectifier
systems apply voltages of 50-100 Kilovolts at relatively high current densities. Modern controls
minimize sparking and prevent arcing, avoiding damage to the components. Automatic rapping
systems and hopper evacuation systems remove the collected particulate matter while on line
allowing ESP‟s to stay in operation for years at a time.
OPERATION OF BOILER
The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are
made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter.
Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly
burns, forming a large fireball at the center. The thermal radiation of the fireball heats the water
that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the
boiler is three to four times the throughput and is typically driven by pumps. As the water in the
boiler circulates it absorbs heat and changes into steam at 700 °F (370 °C) and 22.1 MPa. It is
separated from the water inside a drum at the top of the furnace. The saturated steam is
introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as
they exit the furnace. Here the steam is superheated to 1,000 °F (540 °C) to prepare it for the
turbine.
The steam generating boiler has to produce steam at the high purity, pressure and temperature
required for the steam turbine that drives the electrical generator. The generator includes the
economizer, the steam drum, the chemical dosing equipment, and the furnace with its steam
generating tubes and the superheater coils. Necessary safety valves are located at suitable
pointsvto avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft
(FD) fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic
precipitator or baghouse) and the flue gas stack.
Schematic diagram of a coal-fired power plant steam generator
OPERATION OF TURBINE
Steam turbines are used in all of our major coal fired power stations to drive the generators or
alternators, which produce electricity. The turbines themselves are driven by steam generated in
'Boilers' or 'Steam Generators' as they are sometimes called. Energy in the steam after it leaves the
boiler is converted into rotational energy as it passes through the turbine. The turbine normally
consists of several stages with each stage consisting of a stationary blade (or nozzle) and a rotating
blade. Stationary blades convert the potential energy of the steam (temperature and pressure) into
kinetic energy (velocity) and direct the flow onto the rotating blades. The rotating blades convert
the kinetic energy into forces, caused by pressure drop, which results in the rotation of the turbine
shaft. The turbine shaft is connected to a generator, which produces the electrical energy. The
rotational speed is 3000 rpm for Indian System (50 Hz) systems and 3600 for American (60 Hz)
systems.
In a typical larger power stations, the steam turbines are split into three separate stages, the first
being the High Pressure (HP), the second the Intermediate Pressure (IP) and the third the Low
Pressure (LP) stage, where high, intermediate and low describe the pressure of the steam. After
the steam has passed through the HP stage, it is returned to the boiler to be re-heated to its
original temperature although the pressure remains greatly reduced. The reheated steam then
passes through the IP stage and finally to the LP stage of the turbine.
High-pressure oil is injected into the bearings to provide lubrication.
VARIOUS CYCLES AT POWER
STATION
COAL CYCLE
CONDENSATE CYCLE
STEAM CYCLE
COAL CYCLE
Coal Stock
Yard
RC Bunker
RC Feeder
Mill
Furnace
Condensate Cycle
From LP
condensor
Turbine
Condensate
Ejector
Pump
Gland
LPH1
Steam
LPH2 LPH3
Dearrator
FFED WATER CYCLE
Main Steam
Final Heater
Line
Cold Reheat
HP Turbine
Line
Hot Reheat
Reheater
Line
Low pressure To
Line Condensor
CONTROL & INSTRUMENTATION
INTRODUCTION
C&I LABS
PRESSURE MONITORING
TEMPERATURE MONITORING
FLOW MEASUREMENT
CONTROL VALVES
INTRODUCTION
This division basically calibrates various instruments and takes care of any faults occur in any of the
auxiliaries in the plant.
C&I LABS
Control and Instrumentation Department has following labs:
1. Manometry Lab
2. Protection and Interlocks Lab
3. Automation Lab
4. Electronics Lab
5. Water Treatment Plant
6. Furnaces Safety Supervisory System Lab
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.
TRANSMITTERS
It is used for pressure measurements of gases and liquids, its working principle is that the input
pressure is converted into electrostatic capacitance and from there it is conditioned and amplified. It
gives an output of 4-20 ma DC. It can be mounted on a pipe or a wall. For liquid or steam
measurement transmitters is mounted below main process piping and for gas measurement
transmitter is placed above pipe.
MANOMETER
It’s a tube which is bent, in U shape. It is filled with a liquid. This device corresponds to a difference
in pressure across the two limbs.
1. Accuracy
2. Safety
3. Utility
4. Price
ACCURACY
Higher Accuracy implies Larger Dial Size for accuracy of small and readable pressure scale
increments.
SAFETY
While selecting Pressure Gauge it should consider that Gauge Construction Material should be
chemically compatible with the environment either inside or outside it.
UTILITY
It should keep it mind that range of the Gauge should be according to our need else Overpressure
Failure may occur resulting in damage of Gauge.
PRICE
Lager the Gauge’s Dial size larger would be our price. Better Gauge’s Construction material also
increses the cost. So they must be chosen according to our need.
2. Protection and Interlock Lab
INTERLOCKING
It is basically interconnecting two or more equipments so that if one equipment fails other one can
perform the tasks. This type of interdependence is also created so that equipments connected
together are started and shut down in the specific sequence to avoid damage. For protection of
equipments tripping are provided for all the equipments. Tripping can be considered as the series
of instructions connected through OR GATE, which trips the circuit. The main equipments of this lab
are relay and circuit breakers. Some of the instrument uses for protection are:.
RELAY
It is a protective device. It can detect wrong condition in electrical circuits by constantly measuring
the electrical quantities flowing under normal and faulty conditions. Some of the electrical
quantities are voltage, current, phase angle and velocity. 2. FUSES It is a short piece of metal
inserted in the circuit, which melts when heavy current flows through it and thus breaks the circuit.
a) The coefficient of expansion of silver is very small. As a result no critical fatigue occurs and
thus the continuous full capacity normal current ratings are assured for the long time.
b) The conductivity of the silver is unimpaired by the surges of the current that produces
temperatures just near the melting point.
c) Silver fusible elements can be raised from normal operating temperature to vaporization
quicker than any other material because of its comparatively low specific heat.
1. HIGH TENSION CONTROL CIRCUIT for high tension system the control system are excited by
separate D.C supply. For starting the circuit conditions should be in series with the starting
coil of the equipment to energize it. Because if even a single condition is not true then
system will not start.
2. LOW TENSION CONTROL CIRCUIT For low tension system the control circuits are directly
excited from the 0.415 KV A.C supply.
The same circuit achieves both excitation and tripping. Hence the tripping coil is provided for
emergency tripping if the interconnection fails.
3. AUTOMATION LAB
This lab deals in automating the existing equipment and feeding routes. Earlier, the old technology
dealt with only (DAS) Data Acquisition System and came to be known as primary systems. The
modern technology or the secondary systems are coupled with (MIS) Management Information
System. But this lab universally applies the pressure measuring instruments as the controlling force.
However, the relays are also provided but they are used only for protection and interlocks.
4. PYROMETRY LAB
LIQUID IN GLASS THERMOMETER –
Mercury in the glass thermometer boils at 340° C which limits the range of temperature that can
be measured. It is L shaped thermometer which is designed to reach all inaccessible places.
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.
2, 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.
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).
ANNUNCIATIN CARDS
They are used to keep any parameter like temperature etc. within limits. It gets a signal if
parameter goes beyond limit. It has a switching transistor connected to relay that helps in alerting
the UCB.
1. Metallurgical
2. Mechanical
Mechanical Problem can 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 Turbine is 1060° C so
temperature should be below the limit. Monitoring of all the parameters is necessary for the safety
of both:
1. Employees
2. Machines
1. Speed
2. Temperature
3. Current
4. Voltage
5. Pressure
6. Eccentricity
7. Flow of Gases
8. Vacuum Pressure
9. Valves
10. Level
11. Vibration
PRESSURE MONITORING
Pressure can be monitored by three types of basic mechanisms
1. Switches
2. Gauges
3. Transmitter type
For gauges we use Bourdon tubes. The Bourdon Tube is a non-liquid pressure measurement device.
It is widely used in applications where inexpensive static pressure measurements are needed.
A typical Bourdon tube contains a curved tube that is open to external pressure input on
one end and is coupled mechanically to an indicating needle on the other end, as shown
schematically below.
For Switches pressure switches are used and they can be used for digital means of monitoring as
switch being ON is referred as high and being OFF is as low.
• Current : 4 – 20 milli-Amperes
We use 4mA as the lower value so as to check for disturbances and wire breaks.
ACCURACY : ± 0.1 %
Programmable Logic Circuits (PLCs) are used in the process as they are the heart of
Instrumentation.
TEMPERATURE MONITORING
We can use Thermocouples or RTDs for temperature monitoring. Normally RTDs are used for low
temperatures.
1. Temperature Range
2. Accuracy Required
In this we use Chromel (Nickel-Chromium Alloy) / Alumel (Nickel-Aluminium Alloy) as two metals.
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 μV/°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
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
isoccasionally misspelled as 'Rotometer'.
It belongs to a class of meters called variable area meters, which measure flow rate by allowing the
cross sectional area the fluid travels through to vary, causing some measurable effect.
A rotameter consists of a tapered tube, typically made of glass, with a float inside that is pushed up
by flow and pulled down by gravity. At a higher flow rate more area (between the float and the
tube) is needed to accommodate the flow, so the float rises. Floats are made in many different
shapes, with spheres and spherical ellipses being the most common. The float is shaped so that it
rotates axially as the fluid passes. This allows you to tell if the float is stuck since it will only rotate if
it is not.
Selection of flow meter depends upon the purpose, accuracy and liquid to be measured so different
types of meters used
.
TURBINE TYPE:
They are simplest of all. They work on the principle that on each rotation of the turbine a pulse is
generated and that pulse is counted to get the flow rate.
VENTURIMETERS :
Referring to the diagram, using Bernoulli's equation in the special case of incompressible
fluids (such as the approximation of a water jet), the theoretical pressure drop at the
constriction would be given by (ρ/2)(v22 - v12).
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
The 95 MW boilers are indirect type boilers. Fire takes place in front and in rear side. That’s why it’s
called front and rear type boiler.
The 210 MW boilers are direct type boilers (which means that HSD is in direct contact with coal)
firing takes place from the corner. Thus it is also known as corner type boiler.
IGNITER SYSTEM
Igniter system is an automatic system, it takes the charge from 110kv and this spark is brought in
front of the oil guns, which spray aerated HSD on the coal for coal combustion. There is a 5 minute
delay cycle before igniting, this is to evacuate or burn the HSD. This method is known as PURGING.
PRESSURE SWITCH
Pressure switches are the devices that make or break a circuit. When pressure is applied, the switch
under the switch gets pressed which is attached to a relay that makes or break the circuit.
Time delay can also be included in sensing the pressure with the help of pressure valves.
Examples of pressure valves:
1. Manual valves (tap)
2. Motorized valves (actuator) – works on motor action
3. Pneumatic valve (actuator) _ works due to pressure of compressed air
4. Hydraulic valve
IT DEPARTMENT
IT BTPS VISION
IT APPLICATION @BTPS
2. Procurement & Maintenance of IT Infrastructure ( PCs, Printers, Servers & Network LAN,WAN
etc)
IT APPLICATION @ BTPS
At BTPS, Information Technology has been used extensively to manage following business
processes-
1. OPERATIONS
Important & critical parameters of Power Plant operation are monitored online to enable effective
control on operation of various equipments and reduce down time. Online load analysis & Generation
values are monitored to have optimum load balance of various units. Auxiliary power consumption
monitored and controlled. Meritorial operation practicing enabled.
2. MAINTENANCE
Better control over maintenance cost by way of online information available through the system.Based
on failure analysis and equipment history, modified maintenance strategy of Preventive, Predictive and
Risk Based maintenance is implemented. Equipment spares planning are streamlined by way of Annual
requirement, Vendor wise, linked to Equipment, Standardization of defects and repair codes for easy
filling of Work Order Card, for future analysis.
3. MATERIALS
Material Planning and Procurement system streamlined, resulting in reduction in Administrative lead
Time. Further, procurement on Annual Rate Contract basis enabled through the system, Ordering on
actual need basis (just in time). This further reduces lead time and Inventory carrying.
Detection of duplicate and obsolete items, standardization of material description and specification,
Cleaning and Weeding of redundant data, resulting in overall system improvement and functionalities,
Availability of coal stock status online, reduction in demurrages paid to railways.
E-Desk , E-Broadcast,
SMS & E-Mail as Primary
E-SERVICES OFFICE KEY FOCUS AREA
Communication &
AUTOMATION & TOWAREDS PAPERLESS Document Delivery
COMMUNICATION OFFICE System.
REFERENCE
TRAINING REPORTS OF PAST YEARS AT NALANDA LIBRARY
INTERNET
DOCUMENTS OF IT DEPARTMENT