INDEX 1. Acknowledgements 2. About the company 2.1. NTPC group 2.2. Evolution of NTPC 2.3.

Electricity from Coal

3. Definition of Automation 4. Benefits of Automation 5. Control Mechanisms 6. Control & Instrumentation 6.1. Manometry Lab 6.2. Protection & Interlock Lab
1

6.3. Automation Lab 6.4. Pyrometry Lab 6.5.Furnace Safety & Supervisory Lab 6.6.Electronics Lab 7. Ecological Monitoring Programme 8. Ash Utilization 9. Environment Management & safety System

List of Figures

Fig. 1 its Growth Fig. 2 Fig. 3

Installed Capacity &

Fortin Barometer Typical

Arrangement of Bourdon Gauge Fig. 4 Dewrance Critical

Pressure Gauge

Fig. 5

Air Purge Level

Measurement Fig. 6 Thermostat Fig. 7 Strip Fig. 8 Liquid Expansion Thermometer with C Bourden Fig. 9 Bulb Forms Helical Bi-Metal Rod Type

Fig.10 Thermocouple

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
6

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.

Figure 1

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
8

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.

2004

NTPC became a listed company with majority

Government of 89.5%.

ownership

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.
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NTPC is the largest power utility in India, accounting for about 20% of Indias installed capacity.

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%

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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%

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GENERATION OF ELECTRICITY FROM COAL

13

Coal from the coal wagons is unloaded with the help of wagon tipplers in the C.H.P. this coal is taken to the raw coal bunkers with the help of conveyor belts. Coal is then transported to bowl mills by coal feeders where it is pulverized and ground in the powered form. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold mixture P.A fan. This fan takes atmospheric air, a part of which is sent to pre heaters while a part goes to the mill for temperature control. Atmospheric air from F.D fan in the air heaters and sent to the furnace
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as combustion air. Water from boiler feed pump passes through economizer and reaches the boiler drum . Water from the drum passes through the down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat density difference the water rises up in the water wall tubes. This steam and water mixture is again taken to the boiler drum where the steam is sent to super heaters for super heating. The super heaters are located inside the furnace and the steam is super heated (540 degree Celsius) and
15

finally it goes to the turbine. Fuel gases from the furnace are extracted from the induced draft fan, which maintains balance draft in the furnace with F.D fan. These fuel gases heat energy to the various super heaters and finally through air pre heaters and goes to electrostatic precipitators where the ash particles are extracted. This ash is mixed with the water to from slurry is pumped to ash period. The steam from boiler is conveyed to turbine through the steam pipes and through stop valve and control valve that automatically regulate the supply of steam to the turbine.
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Stop valves and controls valves are located in steam chest and governor driven from main turbine shaft operates the control valves the amount used. Steam from controlled valves enter high pressure cylinder of turbines, where it passes through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on the disc secured in the turbine shaft. The second ring turns the shaft as a result of force of steam. The stationary and moving blades together.
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AUTOMATION : THE DEFINITION

The word automation is widely used today in relation to various types of applications, automation, automation. This subsection presents the such plant as or office process

application of a control system for

18

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.
19

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 redefines system new set automatically 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 pre20

programmed adaptively controlled load gradients and in a safe way.

AUTOMATION: THE BENEFITS

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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: 1. Optimisation of house load consumption during plant startup, shut-down and operation, via: Faster plant start-up through elimination of control errors creating delays. Faster sequence of control actions compared to manual
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ones. Figures 1 shows the sequence of a rapid restart using automation for a typical coal-fired station. Even a welltrained 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.

2. Ensure and maintain plant operation, even in case of disturbances in the control system, via:
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 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.

3. Reduce plant / process shutdown time for repair and maintenance as well as repair costs, via: Protection of individual process components against overstress
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(in a stable or unstable plant operation). Bringing processes in a safe stage of operation, where process components are protected against overstress

CONTROL AND MONITORING MECHANISMS

There are basically two types of Problems faced in a Power Plant

25

 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.

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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

27

 Eccentricity Flow of Gases Vaccum Pressure Valves Level Vibration

CONTROL AND INSTRUMENTATION

This division basically calibrates various instruments and takes care of any faults occur in any of the auxiliaries in the plant. It has following labs:
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1. MANOMETRY LAB 2. PROTECTION AND INTERLOCK LAB 3. AUTOMATION LAB 4. WATER TREATEMENT LAB 5. FURNACE SAFETY SUPERVISORY SYSTEM(FSSS) 6. ELECTRONICS TEST 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.

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MANOMETRY LAB
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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: Its a tube which is bent, in U shape. It is filled with a liquid. This device corresponds to a
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difference in pressure across the two limbs. BOURDEN PRESSURE GAUGE :Its an oval section tube. Its one end is fixed. It is provided with a pointer to indicate the pressure on a calibrated scale. It is of 2 types: (a) Spiral type: for Low pressure measurement. (b) Helical Type: for High pressure measurement. Pressure Measurement The U-Tube or Manometer: Liquid contained in a tube bend in the form of a U will respond to a difference in pressure across the two limbs. A
32

glass tube of uniform crosssectional-area is bent to form a U and partly filed with a liquid of known density 'd' p.s.l. Measurement of Atmospheric Pressure: Atmospheric pressure will support calcium of Mercury approximately 30 inches in a U-tube provided a good vacuum is maintained in one limb. Ifa U-tube is replaced with a straight limb about 35 inches long, one end closed, then being filed with clean, dry mercury and then inverted in a container of mercury open to the atmosphere, the mercury would fall in the tube forming a good vacuum above it.
33

34

Fig.2 Fortin.Barometer

Single Tube Manometer This is used for measuring low pressure and for testing and recalibration lowpressure instruments of al types. If the ratio of the area of one tube is considerably greater than other, then practically al the movement takes place in the smal manometer tube and for al practical purposes only the one limb need be read. Kenotometer The low pressures produced in steam condensers are
35

usually measured in inches of mercury, marking downwards from atmospheric pressure. A high working vacuum of 29.5 inches of mercury is the same as an absolute pressure of 0.5 inch of mercury, or approximately 0.25 p.s.i (absolute). One device for measuring the absolute pressure in a condenser is the Kenotometer. Bourdon Pressure Gauge: This is the most commonly used of al pressure measuring devices. (Range 10- 80,000 p.s.i). Here, a tube of oval section is bent into a circular arc. One end is sealed and the other end fixed to a solid block into which the applied pressure is fed. The tube
36

will "uncurl" as the pressure (operating Force) increases, or will 'Curl up' as the vacuum increases; so giving a movement of the free end which is proportional to the change in pressure. The Controlling Force will depend upon the thickness of the tube and the material from which it is made.

37

Fig.3 Typical Arrangement of Bourden Gauge SpecialTypes Of Pressure Gauges Spiral Tube: This type is used for low-pressure indication and recording when a C-shaped Bourden tube is not suitable and where power is required. By making the oval tube in the form of a spiral an enlarged movement of the free end is achieved and thus the tube becomes more sensitive over pressure ranges below 10 p.s.i. Helical Tube: For higher pressures the tube is wound in the form of a helix and is often used in pressure recorders. Range 0-80,000 p.s.i.
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Critical Type: This is used in boiler houses to enable distant reading of the steam pressure to be made to the nearest 1 p.s.i over a range of say 15 p.s.i. The movement of a pressure sensitive element is transmitted to a pointer and scale via linkages, which only allow the pointer to operate over a selected range of pressure to either side of the normal steam pressure.

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Fig.4 Gauge

Dewrance Critical Pressure

Measurement of Level
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Direct Methods 'Sight Glass' is used for local indication on closed or open vessels. A sight glass is a tube of toughened glass connected at both ends through packed unions and vessel. The liquid level will be the same as that in the vessel. Valves are provided for isolation and blow down. "Float with Gauge Post" is normally used tor local indication on closed or open vessels. "Float Operated Dial" are used for small tanks and congested areas. The float arm is connected to a quadrant and pinion which rotates the pointer over a scale.
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Pressure operated types Since the pressure acting on any area at the bottom of a tank depends only upon the depth and density of the contained liquid, a measure of this pressure is proportional to the liquid level. Bourden Pressure Gauge A Bourdon pressure gauge calibrated in any fact head is often connected to a tank at or near the datum level. "Mercury Manometer" is used for remote indication of liquid level. The working principle is the same as that of a manometer one limp of a U-tube is connected to the tank, the other being open to atmosphere. The manometer liquid must not mix with
42

the liquid in the vessel, and where the manometer is at a different level to the vessel, the static head must be allowed in the design of the manometer. 'Diaphragm Type' is used for remote level indication in open tanks or docks etc. A pressure change created by the movement of a diaphragm is proportional to a change in liquid level above the diaphragm. This consists of a cylindrical box with a rubber or plastic diaphragm across its open end as the level increases .the liquid pressure on the diaphragm increases and the air inside is compressed. This pressure is transmitted via a
43

capillary tube to an indicator or recorder incorporating a pressure measuring element. Sealed Capsule Type The application and principle is the same as for the diaphragm box. In this type, a capsule filed with an inert gas under a slight pressure is exposed to the pressure due to the head of liquid and is connected by a capillary to an indicator. In some cases the capsule is fitted external to the tank and is so arranged that it can be removed whilst the tank is still full, a spring loaded valve automatically shutting of the tapping point.
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Air Purge System This system provides the simplest means of obtaining an indication of level, or volume, at a reasonable distance and above or below, the liquid being measured. The pressure exerted inside an open ended tube below the surface of a liquid is proportional to the depth of the liquid.

Fig.5 Measurement

Air Purge Level

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PROTECTION AND INTERLOCK LAB

INTERLOCKING : It is basically interconnecting two or more equipments so that if one equipments fails other one can perform the tasks. This type of interdependence is also created so that equipments connected together are started and shut down in the specific sequence to avoid damage. For protection of equipments tripping are provided for all the equipments. Tripping can be considered as the series of instructions connected through OR GATE. When a fault occurs and any
46

one of the tripping is satisfied a signal is sent to the relay, which trips the circuit. The main equipments of this lab are relay and circuit breakers. Some of the instrument uses for protection are: 1. RELAY : It is a protective device. It can detect wrong condition in electrical circuits by constantly measuring the electrical quantities flowing under normal and faulty conditions. Some of the electrical quantities are voltage, current, phase angle and velocity. 2. FUSES: It is a short piece of metal inserted in the circuit, which melts when heavy current flows through it
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and thus breaks the circuit. Usually silver is used as a fuse material because: a) The coefficient of expansion of silver is very small. As a result no critical fatigue occurs and thus the continuous full capacity normal current ratings are assured for the long time. b) The conductivity of the silver is unimpaired by the surges of the current that produces temperatures just near the melting point. c) Silver fusible elements can be raised from normal operating temperature to vaporization quicker than any other material because of its comparatively low specific heat.
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3. MINIATURE CIRCUIT BREAKER : They are used with combination of the control circuits to. a) Enable the staring of plant and distributors. b) Protect the circuit in case of a fault. In consists of current carrying contacts, one movable and other fixed. When a fault occurs the contacts separate and are is stuck between them. There are three types of - MANUAL TRIP - THERMAL TRIP - SHORT CIRCUIT TRIP

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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.
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However, the relays are also provided but they are used only for protection and interlocks. Once the measured is common i.e. pressure the control circuits can easily be designed with single chips having multiple applications. Another point is the universality of the supply, the laws of electronic state that it can be any where between 12V and 35V in the plant. All the control instruments are excited by 24V supply (4-20mA) because voltage can be mathematically handled with ease therefore all control systems use voltage system for computation. The latest technology
51

is the use of ETHERNET for control signals.

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PYROMETERY LAB

The most important parameter in thermal power plant is temperature and its measurement plays a vital role in safe operation of the plant. Rise of temperature in a substance is due to the resultant increase in molecular activity of the substance on application of heat; which increases the internal energy of the material Temperature Measurement . The change may be observed with substance itself or in a subsidiary
53

system in equilibrium.

thermodynamic

Fig.6

Rod Type Thermostat

Solid Rod Thermometers: A temperature sensing - Controlling device may be designed incorporating in its construction the principle that some metals expand
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more than others for the same temperature range. Bi-Metalic Strip : These are composed of two metals, as the name implies, whose coeficients of linear expansion are dissimilar. These two metal plates are welded together as a sandwich. When heated, both metals expand, but the metal with greatest coeficient of linear expansion wil expand more causing the sandwich to curl up or down depending on the position of this metal.

55

Fig.7 Metallic Strip

Helical Bi-

Liquid in Glass Thermometers : The coeficient of cubical expansion of mercury is about eight time greater that of glass. Therefore, a glass container holding mercury, when heated, wil expand far less than the mercury it contains. At a high temperature the mercury will occupy a greater fraction of the
56

volume of the container than it will at a low temperature. Under normal atmospheric conditions mercury normally boils at a temperature of (347C). To extend the range of a mercury in glass thermometer beyond this point the top end of a thermometer bore opens into a bulb which is many times larger in capacity than the bore. This bulb plus the bore above the mercury, is then filed with nitrogen or carbon dioxide gas at a sufficiently high pressure to prevent boiling at the highest temperature to which the thermometer may be used.

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Mercury in Steel: The range of liquid in glass thermometers although quite large, does not lend itself to al industrial practices. This fact is obvious by the delicate nature of glass also the position of the measuring element is not always the best position to read the result. Types of Hg in Steel Thermometers are: Bourdon Tube : Most common and simplest type Spiral type : More sensitive and used where compactness is necessary

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 Helical Type : Most sensitive and compact.Pointer may be mounted direct on end of helix which rotates, thus eliminating backlash and lost motion.

Fig.8 Liquid Expansion Thermometer with C Bourden

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(1) LIQUID IN GLASS THERMOMETER : Mercury in the glass thermometer boils at 340 degree Celsius which limits the range of temperature that can be measured. It is L shaped thermometer which is designed to reach all inaccessible places.

Fig.9

Bulb Forms

A. PLAIN BULB B. UNION BULB; C. POCKET BULB D. WALL MOUNTING

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E. SHORT COtL. F. LONG COIL; G. FINNED STRAIGHT H.WATCH CAPSULE 2) ULTRA VIOLET SENSOR : 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. (3) 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.
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Fig.10 Thermocouple

(4) RTD (RESISTANCE TEMPERATURE DETECTOR) : It performs the function of thermocouple basically but the difference is of a resistance. In this due to the change in the resistance the temperature difference is measured. In this lab, also the measuring devices can be calibrated in the oil bath or just boiling water
62

(for low range devices) and in small furnace (for high range devices). Gas Thermometers : In Efect of Heat, the volume of a gas. at constant pressure, wil change with relation to temperature change, and that at constant volume the pressure changes in relation to temperature. Therefore, if a bulb, capillary and bourdon tube enclose a certain volume of gas and the both of that assembly is subjected to heat, or change of the same, the changes of pressure, effected by the heat, within the system, can be directly related to temperature. The later will, of
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course be shown though the movement of the free end of the bourdon tube.

FURNACE SAFETY AND SUPERVISORY SYSTEM LAB

This lab has the responsibility of starting fire in the furnace to enable the burning of coal. For first stage coal burners are in the front and
64

rear of the furnace and for the second and third stage corner firing is employed. Unburnt coal is removed using forced draft or induced draft fan. The temperature inside the boiler is 1100 degree Celsius and its height is 18 to 40 m. It is made up of mild steel. An ultra violet sensor is employed in furnace to measure the intensity of ultra violet rays inside the furnace and according to it a signal in the same order of same mV is generated which directly indicates the temperature of the furnace. For firing the furnace a 10 KV spark plug is operated for ten seconds over a
65

spray of diesel fuel and pre-heater air along each of the feeder-mills. The furnace has six feeder mills each separated by warm air pipes fed from forced draft fans. In first stage indirect firing is employed that is feeder mills are not fed directly from coal but are fed from three feeders but are fed from pulverized coalbunkers. The furnace can operate on the minimum feed from three feeders but under not circumstances should any one be left out under operation, to prevent creation of pressure different with in the furnace, which threatens to blast it.
66

ELECTRONICS LAB
67

This lab undertakes the calibration and testing of various cards. It houses various types of analytical instruments like oscilloscopes, integrated circuits, cards auto analyzers etc. Various processes undertaken in this lab are: 1. Transmitter converts mV to mA. 2. Auto analyzer purifies the sample before it is sent to electrodes. It extracts the magnetic portion.

ANNUNCIATION CARDS : They are used to keep any parameter like

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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.

69

ECOLOGICAL MONITORING PROGRAMME NTPC has undertaken a

comprehensive Monitoring Programme

Ecological through

Satellite Imagery Studies covering an area of about 25 Kms radius around some of its major plants. The
70

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 increase have in been dense noticed forest are area,

increase in agriculture area, increase

71

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.

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USE OF WASTE PRODUCTS & SERVICES -ASH UTILIZATION Ash is the main solid waste which is put into use for various products and
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services. NTPC has adopted user friendly policy guidelines on ash utilisation. In order to motivate entrepreneurs to come forward with ash utilisation schemes, facilities NTPC and offers several These

incentives.

include free issue of all types of ash viz. Dry Fly Ash / Pond Ash / Bottom facilities, Ash and infrastructure feasible.

wherever

Necessary help and assistance is also offered to facilitate procurement of land, supply of electricity etc from
74

Government Authorities. Necessary techno-managerial given wherever assistance is

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.
75

76

Environment

Management,

Occupational Health and SafetySystems: NTPC has actively gone for adoption of best international practices on environment, occupational health and safety areas. The organization has pursued the Environmental Management System (EMS) ISO
77

14001 and the Occupational Health and Safety Assessment at its System different

OHSAS

18001

establishments. As a result of pursuing these practices, all NTPC power stations have been certified for ISO 14001 & OHSAS 18001 by reputed national and international Certifying Agencies.

While deciding the appropriate technology for its projects, NTPC integrates many environmental
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provisions into the plant design. In order to ensure that NTPC comply with all the stipulated environment norms, various state-of-the-art

pollution control systems / devices as mentioned below have been installed to control air and water pollution. Electrostatic Precipitators Flue Gas Stacks Neutralisation Pits Low-NOX Burners

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Coal Settling Pits / Oil Settling Pits DE & DS System Cooling Towers Ash Dykes & Ash Disposal systems Ash Water Recycling System Dry Ash Extraction System (DAES) Liquid Waste Treatment Plants & Management System Sewage Treatment Plants &
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Facilities Environmental Institutional Set-up Environment Reviews Up gradation & retrofitting of Pollution Control Systems

81