CHAPTER -01

INTRODUTION
A thermal power station is a power plant in which the prime mover is steam driven. 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 and recycled to where it was
heated; this is known as a rankine cycle.

Commercial electric utility power stations are usually constructed on a large scale and
designed for continuous operation. Electric power plants typically use three-phase electrical
generators to produce alternating current (ac) electric power at a frequency of 50 hz.

1.1 KaTPP OVERVIEW

The site of Kalisindh Thermal Power Project is located in Nimoda, Undal, Motipura, Singharia
and Devri villages of Tehsil Jhalarapatan, Distt. Jhalawar. The proposed capacity of coal based
Thermal Power Project is 1200 MW. The project site is about 12 km from Jhalawar (Distt.
Head quarter ) and NH-12 .It is 2km from state highway No.19 and 8 km from proposed
Ramganj Mandi - Bhopal broad gauge rail line.

The site selection committee of Central Electricity Authority has visited the Nimodha and its
adjoining villages of Jhalawar Distt. and site was found techno-economical feasible for setting
up of a Power Project. The Govt. of Raj. have included that project in 11 th five year plan. The
estimated revised cost of the project is Rs.7723 Crores. M/s. TCE Banglore has been
appointed as the technical consultant for the project. The state irrigation department has alloted
1200 mcft water for the project from proposed Kalisindh dam. The origin of the Kalisindh river
is from northern slop of Vindy After flowing 145 km in Rajasthan, the Kalisindh River merges
in Chambal river near Nanera village of Distt. Kota.Its catchment area is about 7944 sq.km in
Jhalawar & Kota Distt. The existing Dam is located at Bhawarasa village, primarily for
P.H.E.D. purpose is being uplifted for providing a storase of 1200mcft water for this power
project.

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The GOR has alloted 842 bigha Government land and aquired 1388 bigha private khatedari
land for the thermal project .Phase-1 will be constructed on 1400 bigha land only.EPC
contract has been awarded to M/s. BGR Energy System Chennai on dt.09/07/08, through
ICB route at cost Rs.4900 Crores. Ministry of coal, Govt. of India has alloted Paras east
and Kanta basin coal blocks to RVUN in Chhatisgarh state. The RVUN has formed new
company under joined venture with M/s. Adani Enterprises for mining of coal blocks and
new company started the work.

Annual coal requirement for the project is 56 LacsTPA. a Mountains . The river enters
from MP to Rajasthan near village Binda.

Fig. 1.1 KaTPP OUTER VIEW

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TABLE.1.1.INTRODUCTION OF KATPP

Project Kalisindh Super Thermal Power Project Jhalawar

Capacity 1200 MW(2x600 MW)

Village-Undel, Motipura, Nimoda, Singhania & Deveri

of
Project Site
Tehsil Jhalarapatan, Distt. Jhalawar

The project site is about 12 km from NH-12, 2km from state

Project Location highway and 8 km from proposed Ramganj Mandi - Bhopal

broad gauge rail line.

Land Area 2230 Bigha/564 Hq. (1400 bigha/350 Hq. in I stage)

Quantity of Fuel (at

Coal-56 Lacs TPA FO/HSD-13000-14000 KL/A
80% PLF)

Electrostatic
Precipitator 99.98 % Capacity

Stack Height 275 Mtr.

Estimated revised Cost Rs.7723 Crores

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1.2 ENERGY GENERATED IN KaTPP
Total generation Capacity = (2 x 600)
= 1200 MW

Total generated Electricity (in one hour) = 1200 MW x 1

=12.00 Lakh units
Total generated Electricity (in 24hours) = 12.00 x 24
= 288.0 Lakhs units
Amount of Coal required (per day) in KaTPP is = 0.5 x 288.0 x 100000 Kg.
= 144million k

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 CHAPTER-2
GENERAL LAYOUT AND BASIC IDEA

A control system of station basically works on Rankin Cycle. Steam is produced in Boiler is
exported in prime mover and is condensed in condenser to be fed into the boiler again. In
practice of good number of modifications are affected so as to have heat economy and to
increase the thermal efficiency of plant.

Fig. 2.1 PLANT OVERVIEW

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 CHAPTER-3
CONTROL ROOM
3.1 Main Control Room
In control room various controls are provided simultaneously various measurement are made
various relays are provided here. Instrumentation Limited Kota is major supplier of apparatus.
There is one unit control from which two adjacent unit of 110 MW each can be controlled. In
addition are local panels at the boilers, turbo sets and boiler feed pumps. The operation of unit
is basically controlled from unit control room.

The operation of various rents and chain are done locally as per requirement. The unit control
room has a set of parameters panel for indicating or recording parameter of boilers or turbo
sets.

The parameters recorded in control room included per pr. and temp. of line steam, reheat steam,
feed water, fuel oil flow, mill outlet temp. , mill differential, turbine speed, control valve
operation, turbine shaft, axial shaft, back pressure in condenser, metal temperature etc. There
is a data logger to ensure accurate lagging of essential data.

The VCB also control panel for one generator and contains exciter synchronizing arrangement
.The scheme of control and instruction is provided to control the parameters and safe operation
of equipment. Automatic control is provided for combustion for feed water regulation and
reheat temp. The combustion control is designed to inlet maintain the desired steam pressure
at turbine only variation thereof utilized to very fuel input to the boiler w.r.t. steam pressure.
Ratio steam flow maintained automatically.

The feed water regulation is based on impulses from drum level, feed water flow to boiler and
steam flow for the boiler.

Super heater temp. counted with feed water spray. The furnace draft control of draft fan .The
boiler oil system is provided with itself control for ignition control and also provided with
safety interlock to prevent operation under low oil pressure and temperature.

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3.2 CONTROL PANEL-I

3.2.1 FAN CONTROL DESK

a) Induced draft fan ( 3 Nos.) at full load and 2 Induce Draft Fans Run

b) Forced draft fan ( 2 Nos.)

c) Primary Air Fan (3 Nos.) at full load

d) Furnace pressure

e) Primary Air Header Pressure (750-800 mm level)

f) FO Wind box pressure or wind box differential pressure.

3.3 CONTROL PANEL-II

3.3.1 FUEL CONTROL DESK

a) Coal, oil flow

b) Oil pressure

c) Temp. of mill (inlet & outlet)

d) Flow of air

e) Differential Pressure of mill

3.4 CONTROL PANEL-III

3.4.1 STEAM & WATER DESK

a) Drum Level Control

b) Flow of steam & water

c) Pressure of Steam & Water

d) Temp. of steam and water

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3.5 CONTROL PANEL-IV

3.5.1 TURBINE DESK

a) Pressure Control

b) Load Control

c) Speed Control

d) Effectors, Control Values, Stop Values, Derators

3.6 CONTROL PANEL-V

3.6.1GENRATOR CONTROL PANEL

a) Voltage Current MVAR

b) Stator Rotor Temperature

c) For Stator Cooling (i.) H2 pressure (ii.) H2O pressure

Fig. 3.1 CONTROL ROOM

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 CHAPTER-4
CONTROL AND INSTRUMENTATION SYSTEM
4.1 Introduction

Globalization, Privatization and Liberalization has effected power sector also.

Itisgradually moving from a regulatedtoanon-regulated It is gradually moving from a

regulated to a nonregulated system with high competition.

For achieving above in fast manner increasing the efficiencies of electric generating plants is
critical.

Power Plants efficiency is dependent on quality of its operations and maintenance and C&I
has a crucual role in it.

C&I has very important role in stabilization of various system of Power Plant through tuning
and commissioning of various Loops performance monitoring of various subsystems optimal
operation of the plantat the target performance level optimal operation of the plant at the
target performance level Prevent Tripping and Forced shutdowns

Use of Latest C&I systems has resulted in increase in PLF and decreasing the man power
required per MW. and decreasing the manpower required per MW.

4.2 OBJECTIVE OF C&I SYSTEMS

Safe operation of plant Saeopeatoopat

Better visibility, close monitoring of Plant parameters and events for fault analysis

Lower the cost of generation

Increase equipment life

Minimize environmental effect

Maximize efficiencyy

Energy conservation

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4.3 DDCMIS SYSTEM
THIS SYSTEM CONSISTS OF OLCS,CLCS AND OTHER INTERFACE SYSTEM
PANELS. Each panel consists of Power supply module, Processor, Local Bus modules, Input and
output modules (Analog and Digital),Intra plant modules ,diagnostic modules and Interface modules
either all or except one or two.

4.3.1 SYSTEM DESCRIPTION:

a) OLCS(CRB)Panels
These panels are used for operating single Drive in open loop control system mode. In this
outputs are not controlled but monitored. Feedbacks, commands and other parameters for drive
are monitored through MMI. There are 22 such modules for NTPC; CRB 01 to 22.

b) CLCS(CRA) Panels
These panels are used for operating Single drive in CLCS mode i.e. the output is controlled by
taking a fraction of output as a controlling input to the system. There are 15 such closed loop
control system panels in NTPC site. They are labeled as CRA 01 to 15.

c) IS Panels
These panels are used for interfacing IPB with PC-AT. There are such 6 modules in NTPC
site; labeled as CRC 01 to 06.

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Fig. 4.1 DDCMIS ARCHITECTURE

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 CHAPTER-5
POLLUTION CONTROL SYSTEMS
In order to ensure that NTPC comply with all the stipulated environment norms, various
pollution control systems / devices as discussed below have been installed to control air and
water pollution.

5.1 Electrostatic Precipitators

The ash left behind after combustion of coal is arrested in high efficiency. Electrostatic
Precipitators (ESPs) and particulate emission is controlled well within the stipulated norms.
The ash collected in the ESPs is disposed to Ash Ponds in slurry form.

5.2 Flue Gas Stacks

Tall Flue Gas Stacks have been provided for wide dispersion of the gaseous emissions (SOX,
NOX etc) into the atmosphere.

5.3 NeutralisationPits

Neutralisation pits have been provided in the Water Treatment Plant (WTP) for pH correction
of the effluents nbefore discharge into Effluent Treatment Plant (ETP) for further treatment
and use.

5.4 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.

5.5 Ash Water Recycling System:

In the AWRS, the effluent from ash pond is circulated back to the station for further ash
sluicing to the ash pond. This helps in savings of fresh water requirements for transportation
of ash from the plant.

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 CHAPTER-6
GENERATOR
Generator is the main part of thermal power station or any power plant. A generator is a
machine which converts mechanical energy into electrical energy.

The generator has gas cooling construction enclosing the stator winding, core and hydrogen
coolers .The cooling medium hydrogen is contained within the frame and circulation by fans
mounted on either ends of the rotor .The generator is driven by directly coupled steam turbine
at a speed of 3000 rpm.

Provision has been made for circulating the cooling water in order to maintain a constant
temperature of the coolant i.e. H2 as measured at the fan section Side which is in touch with
the temperature of the winding, core and other parts as per load

Each of the 2 units have been provided with 3-phase turbo generator rated output 706MVA,
18.525KA, 22KV, 0.85 lagging p.f., 984 rpm and 50 cycles/sec .The generator has closed loop
of hydrogen gas system for cooling of the stator and rotor at a pressure of 4.5kg/sq-cm(g). Is
filled in a gas tight outer casing of the generator. H2 gas circulates inside the casing by two
single stage rotor mounted fans on either side of the rotor .The heated H2 is in turn cooled by
six surface type water coolers axially mounted inside the generator casing .The cooling water
is supplied to H2 coolers from the BCW overhead tank.

Each generator has terminal led out of its casing and a star point is formed by sorting the neutral
side terminals by a sorting bar. The neutral is grounded by a 1-phase 11000/220V, Neutral
grounding transformer, whose secondary coil is laminated by laminated strip with mechanical
ventilating holes, is connected across a 650V, class 0.4 ohm, 50 kW neutral grounding resistors
and relays for protection of Generator against stator earth faults and stator in turn faults (rating
1 amp).

The H2 gas inside the generator casing is prevented from leaking in between the rotor and
shields, by a continuous oil film maintained between the rotor and sealing rings .The shaft
sealing system have two independent oil sources associated pumps, regulators, coolers filters,

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electrical controls and alarm system. Two independent oil sources are provided for air side and
H2 side sealing rings. The oil circuit of the H2 side of the shaft seal is closed and the oil is
vacuum treated. In KaTPP QFSN-600-2-22F type turbine used.

Fig. 6.1 GENERATOR

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 CHAPTER-7

CONCLUSION

The first phase of Practical Training has proved to be quite fruitful. It provides an opportunity
for encounter with such huge machines like wagon tippler, 600MW Turbines and Generators.

The architecture of the power plant, the way various units are linked and the way working of
whole plant is controlled make the student realize that engineering is not just learning the
structure description and working of various machine but the great part is of planning proper
management.

It also provides an opportunity to lean low technology used at proper place and time can cave
a lot of labor.

But there are few factors that require special mention. Training is not carried to its true spirit.
It is recommended that there should be some project specially meant for students where
presence of authority should be ensured. There should be strict monitoring of the performance
of students and system of grading be improved on basis of work done.

However training has proved to be quite fruitful. It has allowed an opportunity to get an
exposure of the practical implementation to theoretical fundamentals

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 REFERENCE

1. RRVUNL
2. RRVUNAL Report on Power Grid

3. TATA C E Ltd.

4. Report On Thermal Power Design By Govt. Of India.

5. Single Line Diagram by BGR Energy System.

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