1

BRIEF HISTORY OF PLANT

Ever widening gap between the power demand and its

availability in the state of Punjab was one of the basic

reasons for envisaging the thermal plant at Lehra

Mohabbat Distt. Bathinda. The other factors favoring the

installation of this thermal were low initial cost and less

generation period as compared to hydroelectric generating

stations, its good railway connection for fast proximity to

load center. Guru Gobind Singh thermal plant is

Government undertaking (under P.S.E.B.)

Initially it was going to set up at

Bathinda under GNDTP but the air force personal restricted

its set up at Bathinda hence plant site is shifted to Lehra

Mohabbat about 22Km from Bathinda city. Later this plant

was approved as a separate autonomous body with its name

as Guru Hargobind Thermal Plant.

The construction of the plant

commenced in 1992 and its unit started working in

December 1997. Its second unit commenced in August

1998. The main companies whose technology pawed the

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way of this plant are TATA Honeywell & BHEL in turbine

and boiler control .The total set up cost of the plant is 1200

crores and the capacity of the plant is 2 *210 =420 MW. The

over all efficiency of the plant is 95%.

The power availability from the plant now meets

20-25% of the total power requirement in Punjab. It has

gone a long way in ushering prosperity in the state by

emerging a large number of agricultural pumping sets, more

industrial connections, 100% rural electrification, increased

employment potential reliability and improvement in

continuity of supply and system and removal of power cuts

to a great extent. It has also led fast development of

environment in area around District Bathinda by providing

employment to about 3000 persons. Two new units of

250MW each are going to be commissioned soon,

sanctioning of which has already being done.

The following considerations have to be examined in detail

before selection of site for a plant: -

Availability of fuel such as coal.

Ash disposal facilities.

Space requirements.

Nature of land.
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Most important availability of water.

Availability of labour.

Transport facilities.

Public Society problems such as pollution.

Development of backward area.

PROFILE OF THE PLANT

OWNER BOARD Punjab State Electricity

Board

NAME OF THE PLANT Guru Gobind Singh

Thermal Plant

SITE LOCATION Between 129 Km and 132

Km, Milestone on

Bathinda-Barnala Road
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MAIN COMPANIES TATA HONFY WELL and

EVOLVED BHEL

CONSTRUCTION IN 1992

STARTED

COMMENCE MENT IN DECEMBER 1997

OF 1ST UNIT

COMMENCE MENT IN AUGUST, 1998

OF 2ND UNIT

TOTAL SET UP COST 1200 Crores

TOTL CAPACITY OF 420 MW

THE PLANT

TOTAL UNITS IN 2

THE PLANT
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GNERATION COST 112 Paisa/kW

OVERALL EFFICIENCY 95%

OF THE PLANT

HEIGHT OF CHIMNEY 220 Meters Multi Flue

SOURCE OF WATER Bathinda Branch of

Sirhind Canal

POWER DISTRIBUTION

Electric Power Generated here is send to various sectors

through distribution center. This is the main product of the

plant, which is our nations wide requirement. Electric

Power drives all our factories, industries, Railways,

 6

Domestic equipment etc. Overall our life is dependent on

the electric power now days.

Distribution center distributes power from

here to Barnala Sub Distribution Mansa, Bathinda, Delhi,

Ludhiana and Duri as per requirements.

RAW MATERIAL AND THEIR SOURCES

Power generation is using coal, HFS etc. as burning fuels for

the generation of steam from demineralised water.

Coal coming from West Bangal & Bihar via

Rail wagons of 3800 Kcal/kg & 35% ash contents as the

minimum requirement with rate of rupees 680/-p.tone.

&4000 Tons per Day in quantity.

Water is taken from Sirhand canal by the

tunnel link of underground 2600mm dia pipes, which is

collected in water pond of 150 arcs area & capacity 100000

cubic meters.

BASICS OF A THERMAL PLANT

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In a thermal plant, heat energy is converted into mechanical

energy of turbine that is further converted into electrical

energy with the help of generator.

A schematic view of the simplest steam

power plant is shown in fig. A that is on next page.

The three main processes in the diagram are: -

Process AD: - Water is admitted to the boiler,

raised to boiling temperature and then superheated.

Process DF: - The super heated steam is fed to the

turbine where it does work on blades and rotates it.

Process FA: - Heat rejected to the condenser.

Circulating water carries a very large proportion (40-

60% of total heat).

The basic cycle of a steam power plant

considered above is called the RANKINE CYCLE.

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 9

RANKINE CYCLE ON TEMPERATURE

ENTROPY DIAGRAM

The Temperature Entropy (T-S) diagram is the most

useful diagram for illustrating certain fundamental points

about steam cycle. Ideal condition for steam cycle on a T-S

diagram is shown in the fig. That is on the page no.2

At point A the condense is at boiling

temperature corresponding to the back (condenser)

pressure. Heat (sensible) is added to this water to raise

its temperature and pressure. At the point B, it reaches it

saturation temperature. Evaporation begins at point B.

Heat (latent because no rise in temperature between B &

C, as evident from the diagram) addition continues. At C

all the water evaporates and super-heating commences.

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This is shown by the curve CD and at D, the superheated

temperature is achieved.

Steam then expands as it enters the

turbine and rotates it, as shown in the line DEF. At point

E there is no super heat left in the steam and so from E

to F there is increasing wetness. At F steam is passed out

to the turbine to the condenser and condensation of

steam takes place as represented by the line FA. At point

A the steam has all been considered and condense is a

boiling temperature ready to begin another cycle.

To summaries the above:

AB - Heating of feed water (i.e. sensible heat

Addition)

BC - Evaporation of water in boiler (i.e.

Latent heat addition)

CD - Superheating of steam (i.e. superheat

Addition)

DF - Expansion of steam in turbine, point E

Donates demarcation between super-

heated and wet steam.

FA - Condensation of steam in condenser.

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PROCESS OF POWER GENERATION: -

A generating unit of thermal plant consist of boiler unit, a

turbine with accessories, a generator, a unit transformer

and other equipment all arranged to operate as

complementary part of a complete monolithic set. The plant

Overview diagram, which shows the process of generation of

electricity, is on the next to next page.

ELECTRICITY GENERATION PROCESS

EXPLANATION

The coal travels by the conveyer belts from the

coal handling plant to the coalbunkers from where it is fed

into pulverizing mills; which grind the coal into powder. The

powder coal is carried from the mill by steam of air heated

air in the air heater driven by primary air fan (PA) to boiler

burners where it is blown into the furnace and burns like a

gas a force draft fan provide addition controllable to the

burners to assist combustion. The product of this

combustion is dust and ash. (Ratio of 5to 1) the ash to the

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bottom of the boiler and is periodically sluiced to mash

setting pits .The dust carried in the fuel gas to the

precipitators where it is extracted by high voltage electrodes.

The dust is then conveyed to settling lagoons or removed by

the road for safe. The fuel gas passes by an induced draft

fan (ID) to the chimney. The heat released by the burning

coal is absorbed by long length of tubing which forms the

boiler valves. Inside the tube extremely pure water that is

known boiler feed water is converted by the heat into steam

at high pressure and temperature. The steam is then

superheated in further tubes and passes to the high

pressure (H.P) turbine where it is discharged through the

nozzle into the turbine blades. The energy of the steam

striking the blades make the turbine rotates after passing

through the high-pressure turbine. The steam is returned to

the boiler for reheating before passing through the

intermediate pressure turbine (IPT) and to the low-pressure

turbine (LP). Coupled to the turbine shaft is rotor of the

generator, a large cylindrical electromagnet, so that when

the turbine rotor rotates, other rotor rotates with it. The

generator rotor is enclosed in the stator; which consist of

large coils copper bar in which electricity is produced by the

rotation of magnetic field created by the rotor. The electricity

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from the stator winding goes to a transformer; which

increase its voltage so that it can be transmitted over the

power lines into grid system. Mean while, the steam that is

exhausted its useful energy in turning the turbine is turned

back into water in the condenser so that it can be

Used again in the boiler. Before entering in the boiler at the

economizer the water is pumped by condense extract pumps

heated in the low pressure (L.P.) heaters, deaerated in the

deaerator increased in the pressure by boiler feed pumps

and heated further in high pressure (HP) heaters. The water

passes through the economizer to the steam drum then up

through the furnace walltubing before returning to the

steam drum for steam separation. The steam leaves the

drum and heated further in the super heater on its way to

the HP Turbine. The condenser contains miles of tubings

through which the cold water is constantly pumped.

The diagram showing this whole process is

shown on page no. 11& page no. 12

Plant overview

COAL PLANT

Conveyer belt

BOILER BUNKERS
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PULVERISING MILLS

BOILER BURNER
FD Fan

COMBUSION
Dust
Ash

CLEARED FUEL GAS PASS TO CHIMNEY

VIA INDUCED DRAUGHT FAN

COAL BURN

Heat released
BOILS WATER WHICH GIVES STEAM

STEAM IS SUPERHEATED

PASSES TO H.P TURBINE

Continue On Next Page

CONTINUED FROM THE LAST PAGE:-

EXHAUSTED STEAM CONDENSER USED AGAIN IN

ENERGY BOILER

WATER IS PUMPED
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Steam
TURBINE BLADES

CAUSES TURBINE HEATED IN LP HEATERS

TO ROTATE

DEAERATED IN
STEAM IS RETURNED TO
DEAERATOR
BOILER FOR REHEATING

PRESSURE INCREASES
TIRBINE SHAFT IS COMPLED BY BOILER FEED PUMPS
TO ROTOR OF GENERATOR

GENERATOR ROTOR IS HEATED IN HP

ENCLOSED IN STATOR HEATERS

ELECTRICITY IS PRODUCED AT ECONOMIZER

STATORWINDINGFROM WHICH
IT GOES TO TRANSFORMER
STEAM DRUM

POWER IS STEPED UP
BY TRANSFORMER STEAM IS HEATED
Power Lines IN SUPERHEATER

GRID SYSTEMS
HP TURBINE

PLANT OVERVIEW

BLOCKS DISCRIPTION
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SUPERHEATER (SH)

Super Heater (SH) is a plain tubular, non-drainable vertical

in line spaced type, arranged for parallel flow. This super

heater (SH) is located in the horizontal path after reheater.

Next to Super Heater is Reheater System.

REHEATER SYSTEM (RH)

The reheater section is the single stage; spaced type,

continuous loop, and plain tubular, non-drainable, vertical

in line spaced type, arranged for parallel flow.

ECONOMISER SYSTEM (ECON)

The economizer system is a single block unit, is of

continuous loop plain tubular, drainable horizontal, in line

arrangement with water flow upwards and gases flow

downwards. The economizer tubes are suspended from

economizer intermediate header, using ladder type

supports.
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DEAERATOR (DEA)

The deaerator (DEA) is provided to remove dissolved

corrosive gases from feed water that goes to the boiler. It

prevents internal corrosion of boiler tubes. The oxygen is

reduced to untraceable limits by mechanical means in the

condense living the deaerator.

BOILER FEED PUMP (BFP)

Boiler feed pump (BFP) is very important auxiliary of the

powerhouse. It has to take supply of water from the

deaerator, and supply it to boiler drum against the positive

drum pressure.

MILLS

Bowl mills have been installed from pulverizing the raw

coal. The coal of maximum size of 25 mm is received in raw

coalbunkers from Coal Handling Plant. From the bunker,

this coal is fed into the mill through Raw Coal Feeder.
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Regulating the speed of the Feeder can control the feed of

the coal mill.

CONDENSER (COND)

The condenser (COND) is a box type double pass with

divided water box design that facilitates the operation of one

half of the condenser while the other half is under

maintenance. The steam space is of rectangular cross

section to achieve optimum utilization of the enclosed

volume for necessary air-cooling section at the center from

where air and non-condensable gases are drawn out with

the help of air evacuation pumps. The circulating water

enters the water boxes from bottom and then travels

through several tubes and leaves the condenser through

upper water boxes in two distinct paths. Next to condenser

is condensate extraction pump (CEP).

CONDESATE EXTRACTION PUMP (CEP)

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There are two 100% capacity condensate extraction pumps

(CEPs) provided in the system. Normally, one condensate

extraction pump runs and other is kept as stand-by. These

pumps are of vertical and centrifugal canister type with the

driving motor. Condensate extraction pumps have five

stages.

GLAND STEAM COOLER (GSC)

The gland steam cooler is used to condense the steam

extracted from turbine glands and to maintain slight

vacuum at the turbine glands to avoid steam leakage to

atmosphere from turbine glands. It is a single pass heat

exchanger with the main condensate entering from one end

and leaving from the other end. Air steam mixture passes

over the tubes in zigzag path due to number of baffles and

thus steam is condensed there-by heating the condensate

inside the tubes.

DRAIN COOLER (DRN CLR)

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Drain cooler (DRN CLR) is provided to sub cool the drains

coming from Low Pressure (LP) Heater to improve the cycle

efficiency by heating up the condensate flowing through the

tube system.

LP HEATERS (LP HTRS)

The LP heaters (LP HTRS) are of the surface cooled type.

They are designed for vertical mounting. These heaters are

of tube system withdrawal type; these are of four-pass

design. Condensate flows inside the tubes while steam flows

Outside the tubes. The condensed steam is collected in the

bottom of the shell that is drained out.

H.P. HEATER (HP HTRS)

High Pressure heater is supplied heating steam from

extraction 5 taken from IP casing of turbine. The feed water

enters first in this H.P heater and after getting heated goes

to High Pressure (HP) heater 6. The feed water flows through

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the tubes from coldest zone to the hot most zones before it

leaves the heater. The steam flows from hot most zones to

coldest zone and the drain normally goes to deaerator.

ROTARY AIR HEATER (RAH)

The basic principal of operation of Rotatary Air Heater

(RAH) is the same as the liung storm type except that the

elements are stationary and the air hoods rotate with. In

the gas pass at approximately 1 rev./min. The axis of

rotation may be vertical or horizontal but again and for

similar reasons the vertical spindle is preferred. The drive is

normally through an electric motor operating a pinion that

meshes with the rack on the outer rim of the hood

assembly.

FORCED DRAFT FANS (FD FAN)

To take air from atmosphere at ambient temp. To supply

essentially all the combustion, air can either be seized to

overcome all the boiler losses (pressurized system) or just

put the air in the furnace (balanced draft units).

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INDUCED DRAFT FANS (ID FANS)

Used only in balanced draft units to suck the gases out of

the furnace and throw them into the stack. Handles fly ash

laden gases at temperature of 125 to 250 oC.

ELECTROSTATIC PRECIPETATORS (ESP)

The principles upon which Electrostatic Precipitators

operates are that the dust-laden gases pass into a chamber

where the individual particles of dust are given an electric

charge by absorption of free ions from a high voltage DC

ionizing field. There are four different steps in the

precipitation viz., ionization of gases and charging of dust

particles, migration of the particle to the collector,

deposition of charged particles on the collecting surface,

dislodging of particles from the collecting surface.

VARIOUS CYCLES INVOLVED IN

POWER GENERATION
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PRIMARY AIR CYCLE: -

The primary air, generated by PA (primary air) fans, is used

to carry the pulverized coal from the coal mils to the

furnace.

The Primary Air (PA) fans are two in number. A

header called the PA fan duct of the air is made and two

tapings are made from this header. One is passed through

the AIR PRE-HEATER A and B, which, using the heat of the

outgoing flue gases, heats the air, now called the hot

primary air. This hot primary air is now divide into six parts

A to F and then sent to the six coal mills by making a hot

primary air header.

The other tapping of air called the cold primary

air is also made into a cold primary header and then

divided into six parts A to F to be sent into six mills.

Now lets consider the action of primary air on

the mills by considering, say, mill A. Hot primary air A and

cold primary air A pass through respective valves in their

pipes before entering the coal mill. The valve is installed as

the inlet flow temperature is to be maintained at >175C

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and the flow of the air flowing in the mill is to be at 54-

tons/hr.the outlet temperature is to be maintained at >65C

&< 10C.

From the mill, four feed outlet are taken,

carrying the coal to furnace. As these are six mills, so there

are 24 feeds to furnace.

The feed from each mill enters the furnace at

4 different corners but at the same elevation or height. The

feed from other mills also enters the furnace at corners but

at different elevations.

All the feeds from the mill open equally. Now

consider only one corner of the furnace. The feed from mill

A enters the corner of the lowest elevation and those from

mill F at highest elevation. The other feed is between them.

In between feeds A & B, C& D, E & F, there are oil guns

called feed AB, CD, and EF respectively. Below A and above

F, There are auxiliary air inlets in the furnace. The primary

air cycle is shown on the next to next page.

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SECONDARY AIR CYCLE: -

The forced draft fans are used to generate the secondary air,

which is used to help in the ignition and burning of the coal

in the furnace. A common header is made of the two FD

fans (A&B) and this passed through the two air pre-heaters,

which heat the air using the heat from the flue gases, so

that the cold air doesnt bring down the temperature of the

furnace. The secondary air for combustion is preheated up

to 317oC by means of regenerative air-heaters (Rotary Air

Heaters). The air heater air out ducts are interconnected to

provide a balanced air flow to the furnace and to make it

possible to operate the unit at reduced load if one fan is out

of service.
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Distribution of secondary air to Wind Box compartments is

controlled by the secondary air dampers. The steam coil air

pre-heaters (SCAPH) one each at the outlet of FD Fans &

before RAH has been provided to avoid the corrosion of RAH

by increasing the temperature of secondary air entering the

RAH when the boiler is initially lighted up. The secondary

air path is shown in fig. That is on the next page.

Air I/l PA RAH MILLS

FAN A&B A-F
A&B

PRIMARY AIR CYCLE

FURNACE

FD SCAPH RAH
Air I/l FAN A&B A&B
A&B
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SECONDARY AIR CYCLE

AIR CYCLE

FLUE GAS CYCLE: -

Flue gases travel upward in the furnace and downward

through the rear gas pass to the economizer and air

heaters. In the economizer, the some heat of flue gases is

utilized to heat the feed water before it goes to drum.

Further in the air heaters, the residual heat of the flue

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gases is utilized to pre-heat the secondary and primary air.

From the air heaters, the gases pass through the

electrostatic precipitators (ESP) and induced draft fans to

the stack. Interconnections of the gas ducts at inlet and

outlet of electrostatic precipitators are provided.

RAH ID FAN
FURNACE ESP A, B, C
A&B

CHIMNEY
OR
FLUE GAS CYCLE STACK
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WATER CYCLE: -

The steam after working in three casings of the turbine i.e.

HP, IP & LP casings is condensed in the surface condenser

installed just below the LP exhaust hood. The condensate is

collected in the bottom portion called ho well from where it

is pumped into the Deaerator by condensate extraction

pump (CEP) through different heating stages through which

condensate flows and get heated up gradually before finally

reaching the Deaerator. The various heating stages are

Gland Steam Cooler, Drain Cooler, and LP Heater (1, 2, 3)

Deaerator. The approximate temperature rise of condensate

after passing through above heating stages is from 40/45 at

hot well to 166oC at the Deaerator (at full load).

The condensate coming from LP heaters passes the tubes of

vent condenser. The steam transfers its heat to condensate

flowing within the tubes and gets condensed. The non-

condensable gases along with some steam go out of the

equipment. The drain (condensed steam) is returned to the

deaerating header.
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The condensate after leaving the

deaerating header enters the feed storage tank. From feed

water tank, the boiler feed pumps takes suction of feed

water thorough booster Pumps and discharge is fed to the

boiler drum after passing through different heating stages

viz. HP heaters (5, 6) and feed water regulation station (FW

REG STN).

FM DM
M/U

steam COND. CEP GSC DRN

A&B CLR

LP
HTRS

FW HP BFP DEA
REG STN HTRS 5,6 A, B, C

FURNACE

MAIN WATER CYCLE

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STEAM CYCLE

Steam is that part of the whole process cycle in which the

fluent is steam i.e. part of the cycle containing steam.

Steam is first of all generated in the boiler with the help of

coal as a principal fuel. If it is not present in the adequate

amount or not of high purity then heavy furnace oil (HFO)

and light diesel oil (LDO) is used to produce heat in the

furnace.

The heat energy supplied in the furnace is

absorbed by the water walls and gets heated up. This gives

rise to the formation of steam bubbles in the water walls

and the risers. The cold water in the drum there

continuously displaces the moisture of steam bubbles and

water by destabilizing a natured circulation. With the help

of super heater (SH) the steam is super heated and passes

to the HP Turbine. For high efficiency, the turbine is divided

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into three stages viz. HP Turbine, IP Turbine and LP

Turbine. Now at the starting the temperature of the shaft of

the turbine is less and at once increase in temperature may

cause Sag in it therefore few cycles of heated steam passes

through the HP BP so that the conductor in the turbine

may achieve the equivalent temperature of the steam by this

there will be no loss of heat due to temperature difference.

Through HP BP it again passes through the furnace and

there it reheats with the help of Repeater (RH) and then it

passes to the IP Turbine at a temperature of about 551 oC .

From here it passes through the LP Turbine that rotates the

coils of the generator and electricity has been produced.

Like HP BP, LP BP is present as a direct passage of heat

from IP Turbine to condenser where this steam is again

changed into water.

MAIN STEAM CYCLE

HPT
FURNACE
HP BP
ECON SH

RH IPT
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LPT
COND LP BP

GENER
ATOR

WORKING OF THERMAL POWER PLANT AT

G.H.T.P.

Coal received from collieries in the rail

wagons is mechanically unloaded by wagon tippler and

carried by belt conveyor system to crusher house

underground. In crusher house the coal is crushed up to

25mm. This coal is taken by belt conveyer to raw coal

bunkers near coal mill. The coal is then milled to powder

form having up to 0.5mm to1.0mm dia. There is a raw coal

chain feeder that regulates quantity of coal from bunkers to

coal mill where coal is pulverized as said above. That

pulverized coal is then pushed to the boiler furnace by

pressurized primary air from corner feeders. This furnace

 34

have water tube wall all around through which water

circulates. Water is converted into steam by heat released by

combustion of coal. The oils L.D.O.&H.F.O are used in

combustion of coal forced by forced draught fan. That air is

sent in the boiler furnace after heating in air heater by

using the heat of flue gases.

The greatly heated steam and water is

sent to boiler drum, where the water is separated from

steam and the dry steam is sent to the T.G.set, and the

water is again sent to reheater and economizer.

The steam having 130km/m2 to144km/m2 pressure and

5400 c temperature is sent to H.P turbine. Turbine is made

from Germany which uses high pressure steam and rotates

at 3000rpm.The steam used in H.P.Turbine is lost its heat

up to 2400 c so to reheat i.e. to raise again the temperature

and pressure of the steam. The steam is passed through the

reheater and continuously sent to H.P&L.P turbine, made

by B.H.E.L., rotated on the same shaft with 3000rpm. The

steam from LP turbine is taken out in a vacuum condenser

having (-) 0.9kg/cm2 vacuum. Here the steam is condensed

by cold water pipes ciculation.The condensed steam in form

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of hot water is put into the hot wall. From where it is again

feed into the boiler drum through the deaerator, LP heaters,

HP heaters, BFP, Economiser etc. The condensating water,

which is used to condense steam, takes heat from steam

and it becomes hot. That hot water is taken to cooling tower

where it is dropped from 10m heights to cool water by using

natural air draught. This circulation is made by C.W.pumps

And cooling is done up to 100 c.

The products of combustion of

furnace charge are flue gases and ash. About 20%of the ash

falls in the bottom ash hopper of the boiler and is removed

mechanically by mixing with water. The remaining ash

carried by flue gases is separated in the Electrostatic

Precipitator where the ash is electro statically evacuated

And this dry ash is dumped in the ash disposal area. The

cleaned flue gases are left to the atmosphere through 220m

high chimney using I.D.Fan.

The turbines are coupled to the

same shaft upon which the generator is coupled. The Three

phase generator produces 3-phase supply and which is

pumped to the power grid system through generator

 36

transformer by stepping up the voltage which is further

send for distribution.

The raw water is taken from

Sirhind Canal to ponds and after that some amount of

water goes to the boiler through D.M. plant and the

remaining water is clarified and used for the cooling

purposes.
 37

SYSTEM DESCRIPTION
 38

G.H.T.P.Thermal Power Plant consists of various systems.

These are the following systems: -

Coal Handling System.

Fuel oil system

Ash handling system.

D.M. Plant.

Emergency Power supply system.

Control & Instrumentation system.

Data Acquisition system.

Power supply distribution system

COAL HANDLING SYSTEM

G.H.T.P.Thermal Plant is coal-based power plant. The

annual requirement of coal for 2 units based on specific fuel

consumption of 0.60 kg/kwh is 1.381 million tones .The

conveying and crushing system will have the same capacity

as that of the unloading system 1000 TPH.The coal comes

in the coal plant in large pieces. The coal is fed to the

primary crushers, which reduces the size of coal pieces

from400mm to 150mm size. Then the coal is sent to the

 39

secondary crushers through forward conveyors be crushed

from 150mm to 20mm as required at the mills. Then the

coal is sent to mills through coalbunkers .In mills coal

becomes in powder form, which is sent to the boiler with the

help of priamary air fan. The coal is burnt in the boiler.

Boiler includes the pipes carrying water through them.

Heat produced from the combustion of the coal is used to

convert water in pipes into steam. This steam generated is

used to run the turbine. When turbine rotates the shaft of

generated which is mechanically coupled to the shaft of the

turbine get rotated and so 3 phases electric supply is

produced.

FUEL OIL SYSTEM

Fuel oil is normally used for start up and for flame

stabilization at low load. Initially in the boiler either L.D.O.

or H.F.O. is combusted before the combustion of the

crushed coal from the mill.

Light Diesel Oil (L.D.O.) does not require

preheating but Heavy Fuel Oil (H.F.O.) requires preheating

because H.F.O. is very much viscous.

 40

L.D.O. or H.F.O. are used initially because this

oil has less heat of combustion then coal. Heat liberated

from the combustion of these oils is used for starting

combustion of coal as soon as coal starting combustion

L.D.O. and H.F.O.is stopped and coal is supplied

continuously from the fuel guns in to the boiler.

The H.F.O. is preheated by using the heat of

burnt gases, which is coming from boiler of the 2 nd Unit

through Chimney.

ASH HANDLING SYSTEM

When the coal is burnt in the boiler nearly 35% of the ash

is liberated in the addition with another burnt gases. These

ash and gases are coupled out by the reduce draft fan from

the boiler E.S.P. is between the boiler and I.D.Fan. E.S.P.

contains charge electrodes that attract the ash particles and

the collect ash this ash is sent for disposal.

DEMINERALISED PLANT (D.M)

 41

A Demineralised water treatment plant is provided for

supplying make up water to the boiler.

Water as it occurs is never pure as whatever

may be the source always contain impurities .the major

impurities of water are: -

Non-ionic & undissolved

Ionic &dissolved

Gaseous

In the DM plant these impurities are removed chemically &

Demineralised water is sent to the boiler.

EMERGENCY POWER SUPPLY SYSTEM

For the safe shut down of the plant under emergency

conditions i.e. in the case of total power failure diesel

generating sets are purposed to be installed for meeting the

power requirements of the essential auxiliaries.

CONTROL&INSTRUMENTATION
 42

The function of the control & instrumentation system is to

add the operator in achieving the safe and efficient

operation of the unit. The operator is to be provided with

the adequate information considered essential for start up,

normal operation, planned shut down and emergency

shutdown of the unit.

Centralized control of the boiler

&turbine generator unit from a centrally located Unit

Control Board (UCB) room is envisaged. It would be possible

To start or to stop all electrically driven unit auxiliaries

&power operated valves and dampers from UCB expect

where recommended, otherwise, by the main equipment

suppliers.

DATA ACQUISITION SYSTEM

In line with the modern practice of centralized monitoring

and control of large capacity power plants Data acquisition

system (DAS) shall be provided for monitoring and logging of

different parameters of steam generator, turbine, important

temperature points of H.T & L.T motors, generator & other

auxiliaries of the unit.

 43

The system shall monitor, log, the

various parameters at different time e.g. at the time of start

up, shut down, normal run sudden load throw off positions.

The electronic system of DAS shall be of high speed and

equipment with alphanumeric and trend display CRT and

alphanumeric logging printer.

POWER SUPPLY DISTRIBUTION SYSTEM

Power supply/control supply panels with adequate no. Of

spare feeders shall be provided to meet the requirement of

primary instruments, secondary instruments, controls

panels, DAS, sequential control system protection and

interlock system. Suitable arrangement for automatic

changes over from normal supply to stand by supply and

provision of uninterrupted power supply (UPS) to meet the

essential load requirements shall also be provided.

 44

TDC-3000

TDC 3000 organized by process plant instrumentation and

control needs flexibility. Before going in detail of the

TDC-3000 (DCS) we should familiar with the

following objects.

AREA UNIT POINT CONCEPT: -

In TDC-3000 plant instrumentation is classified into areas

and plant can be sub-divided into max. 10 areas.

Collection of points on geographical or

functional sets is identified as units, which in terms are

assigned to respective plant area.

In one area max. 36 units can exist.

Area boiler subdivided into 5 units.

Feed water system (FW)

Steam system (ST)

Flue gas system (FG)

 45

Combustion air system (CA)

Fuel system (FU)

Each unit will have respective set of process data points.

AREA UNIT POINT DIAGRAM

POWER PLANT

BOILER TURBUNE

FU FG CA
FU
AA

TIC FIC
100 100
 46

TIC 100and FIC100: -

Points belonging to steam system unit of boiler area.

Parameters of process points of the total plant (all areas)

can be viewed on any of the universal station (with

operating and universal personality), but process parameter

manipulation and alarm reporting are area specific.

ALARMS AND MESSAGES: -

Alarm and messages will only reported for the points, which

are belonging to the signed units. Whose area database is

currently present in the universal station? Alarm

acknowledgements console wide function.

MANIPULATION OF PROCESS PARAMETERS: -

 47

These are at the operator accessing level. Manipulation of

parameters of the process points will be allowed only for the

points, which are belonging to the assigned units, whose

area database is currently present in universal station.

Manipulation of parameters of the

process points that are not belonging to the assigned unit to

the area database currently present in the universal station,

will be allowed only at the access level higher than that of

operators access level.

ABOUT THE AREA UNIT POINT ORGANISATION: -

1.CONSOLE STATUS: - Unit display target is used to

determine units configured and assigned to the area

database present in the universal station.

2.SYSTEM MENU:-Organization survey menu target to

determine the points attached to individual units of the

area.

WHAT IS TDC3000: -
 48

Total distributed control system (TDC) 3000 is a Honeywell

make DISTRIBUTED CONTROL SYSTEM.

WHAT IS DISTRIBUTED CONTROL SYSTEM:

Functionally and physically separate automatic process

controllers, process monitoring and data logging

equipment, connected with each other to share

relevant information for optimum plant control is

called DISTRIBUTED CONTROL SYSTEM.

HOW DCS CAME IN TO EXISTANCE?

Customer in process industry resulted in advancements in
control and instrumentation(C&I) technology. This
advancement and their advantages and disadvantages are
shown in fig.
 49

Development of (C&I) technology from pneumatic to

electronic equipment was itself a very big change. In

electronic C&I equipment, various functional blocks were

used to function under vinter dependent circuits and

control logic.

At this stage these functions were

interconnected by signals through multiple cables.

 50

Application of microprocessor and

digital communication technique made it possible to

distribute the C&I equipment distributed geographically and

functionally, reducing multiple cable into single cable. This

inter connection of processing function blocks of a system is

termed as a network (N/W)

The signal level and states previously used through multiple

cables are now digital information packets, multiplexed in

time, around the N/w, sent and received by connected

functional processors.
 51

Further advancement allowed the distribution of C&I

system of various type of function n/w like: -

Process N/w

Supervisory N/w

Plant information N/w

Plant wide C&I automation dependent on these N/ws,

emerging as a DCS.

The important benefit of DCS, which is

making it popular is the fact that even failure of processor

or a N/w will not result in failure of other processors or

N/ws of the system respectively.

 52

WHAT ARE THE FUNCTIONS DISTRIBUTED

AROUND A DCS?

Following diagram shows the function blocks in a DCS with

their use:
 53

WHAT IS THE MAIN BENEFITS OF DCS

OVER CONVENTIONAL C&I EQUIPMENT?

Reduction in cabling in control room.

Physically and functionally separate modules.

More uniform operations and tighter controls.

Excellent information management.

Better integration of plant controls.

Considerable reduction over maintenance efforts.

WHEN &FROM WHOM THE FIRST DCS WAS

MADE AVAILABLE?
 54

First DCS came in 1974 from HONEYWELL. It was named

then TDC 2000 (total distributed control 2000). The

communication link in TDC 2000 is called DATA HIWAY.

HOW TDC 3000 THEN CAME INTO

EXISTANCE? AND HOW IT IS ORGANISED?

Further advancement resulted in release of TDC3000 in

1984. This now release of DCS from HONEYWELL contained

new Supervisory LOCAL CONTROL NETWORKK (LCN).

EARLY TDC 3000 SYSTEM ACHITECTURE: -

 55

HONEY WELL TDC 3000 is a data acquisition and control

system that can be tailored to meet the user specific

requirements. It can be small system with just a handful

device, or it may be highly complex system with hundreds of

devices and several kinds of communication networks

interconnecting these devices.

The LCN connected to UNIVERSAL

STATION (US) is used for man-machine interface and

 56

HISTOY MODULE (HM) is used for storage of process

system related information.

Process connected controllers like BASIC

CONTROLLERS (CB) and ADVANCED MULTI FUNCTIONAL

CONTROLLERS (AMC) are linked to LCN through the

process N/w DH and an interface HIGHWAY GATEWAY

(HG).

Further development introduced a new

process N/w UNIVEWRSAL CONTROL N/w (UCN) in

1989.The process N/w is connected to LCN through

NETWORK INTERFACE MODULE (NIM). Capacity of NIM is

higher than HG.

The new TDC 3000 system architecture after inclusion of

UCN and process connected boxes is shown in fig below: -

 57

APM and LM are the UCN connected automatic process

controllers

In various process plants TDC3000 is

practically implemented with redundant communication

medium (cables), gateway and process controllers.

WHAT IS TDC 3000 PROCESS OPERATION:

 58

This means, monitoring and operating the process plant

using universal station of TDC3000 system, this includes: -

Calling various displays.

Monitoring status, values, trends, modes and event on

displays.

Manipulating parameters.

Responding to various alarms and messages.

Taking various hard copies on printers.

Storing important process related information.

Sensors and actuators of various kinds from the process

plant are connected to process controllers through N/ws;

process information (values, status, modes, alarms etc.) is

made available on the US displays.

From US it is possible to manipulate direct

actuator drive, values and mode change of different

parameter in automatic control function, also various

commands to controllers and other N/ws connected

function blocks can be sent from the US.

Monitoring and operation of TDC3000 system

itself is also done at US. Along with process operation,

 59

system operation aspects are also practiced in TDC3000

process operation session

UNIVERSAL STATION

Universal Station is the man machine interface of TDC3000

system. In our subsequent session we will be learning and

practicing above-mentioned activities from US.

US is a single window to the process as well as

TDC3000 system allow the operator both monitored

and manipulate the process the system.

System configuration is also done from Universal

Station.

Before operating TDC 3000 universal station we should be

familiar with the following concepts: -

Universal station equipment.

Universal station personality.

The Access level type of universal station for operating

security.
 60

DIFFERENT PERIPHERAL CONNECTED

TO THE UNIVERSAL STATION (U.S).

Color video display monitor with touch screen facility.

Operators keyboard.

Electronic card rack.

Engineer keyboard (optional).

Cartridge/floppy drive (optional).

Printer (optional).

Trend pen recorder (optional).

Video copier (optional).

Track ball (optional).

DIAGRAM OF US IS SHOWN BELOW: -

 61

1.COLOUR VIDEO SCREEN DISPLAY MONITOR

WITH TOUCH FACILITY: -

Consist of 48cm. (19-inch) high resolution colors CRT

and associated electronics. Each CRT has brightness and

contrast thumb wheels and a degaussing push button on

the bezel. The color video display monitor shows system

displays and process displays.

The touch screen option on the color video display

monitor is implemented using infrared sensor and

transmitters that are located in the bezel of the CRT

screen.

2.OPERATING KEYBOARD: -
 62

Contain 147 touch keys that initiate actions. In this 85

are user configurable function keys & 61 are standard

operated function keys.

Red and yellow color lamps (LEDs) are included on

certain keys to indicate important process and TDC3000

alarm systems.

User Configurable keys are 85 buttons on left side of

operator keyboard, that the user can define or configure

to perform certain functions, such as call up of certain

critical frequently displays. Cross screen displays or to

activate particular action sequence.

Standard Output function keys.61 keys on the right side

of the operator keyboard.

These are further divided into five groups:-

Standard Process displays call &display control keys.

Standard system displays call &system function keys.

Standard process alarm management keys.

Standard operator control keys.

Standard numeric keys.

AC POWER ON/OFF AND ELECTRONICS MODULE

 63

It is the part of the US, helps in AC &DC On/Off control,

main electronic processors, memory, and Local control

network (LCN) interfaces and other interfaces to connected

peripherals and optional devices. Also, the DC power

supply, fan module and necessary interconnecting cable

assemblies for the US are also housed in the same unit.

4.ENGINEER KEY BOARD: -

These are of two types: -

One is fixed in front of operator keyboard.

2
nd
one is plugged into appropriate model of US.

5.CARTRIDGE AND FLOPPY DISK DRIVE: -

Used for random data storage. Both type of disk drives

are compact, easy to use, data storage and retrieval

devices that accept removable magnetic media.

Disk drive: - 5.25-inch floppy diskette called floppy disk

drive. A floppy disk is a flexible; double sided, double

 64

density, enclosed in a sealed jacket and has storage

capacity of 1.2-MB.

Cartridge disk drive accepts cartridge disk. The cartridge

disk is compact and high capacity disk rigidly-encased in

plastic casing. A cartridge drive has storage capacity of

20/40/150 MB.

6.DOT MATRIX PRINTER: -

Take B/w hard copy of various processes & it can print

Logs Reports, Trends and Journals.

Whatever is on the VDM screen, including Graphics?

A record of alarms.

7.TREND PEN RERCORDER: -

Record continuous trend of process values on the

recorder paper.

Up to 8 trends pen can be driven by US.

 65

The trend pen recorders can be mounted on the universal

station within full view of the operation.

8.VIDEO COPIER: -

Video copier is an optional colour copier, which can be

attached with a US to take hard copy of current display on

the VDM screen.

9.TRACK BALL: -

Cursor pointing and target selection device

Front mounted by the operator keyboard panel.

UNIVERSAL STATION PERSONALITY

 66

To service man machine interface needs, following two

software functions termed, as personalities are available for

Universal station (U.S).

OPERATOR PERSNALITY is used for process operation

from US.

ENGINEER PERSONALITY is used for TDC 3000

system configuration for process control engineering

and system maintenance.

With the operating personality present in US,

the operator can: -

Monitor and manipulate process parameter including

startup and shut down of plant units.

View and manage the process and system alarm and

message.

Display and print continuous and discontinuous

histories.

Display and print process trend and averages.

Display and print reports, logs, and journals.

Copy data to/from floppy diskettes or cartridge.

 67

Monitor and change status of system equipment in the

control room and near the process.

Load operating programs and data busses from a history

module, floppy diskettes, or cartridges.

Functions of Operator & Engineer

personalities in single software packed are also available

which is termed as UNIVERSAL PERSONALITY (U.P).

SYSTEM AND PROCESS OPERATION FUNCTION:

Monitoring and controlling continuous and

discontinuous process operation.

Annunciating and handling alarms.

Display and printing trends and logs, journals and

reports.

Monitoring and controlling system status and

diagnostics.

PROCESS ENGINEERING FUNCTIONS: -

 68

Network configuration.

Building process database.

Building custom graphics.

Designing reports.

Preparing control language (CL) programs.

SYSTEM MAINTENANCE FUNCTIONS: -

Diagnosing system problems.

Displaying and printing information required during

troubleshooting.
 69

LOADING OF UNIVERSAL STATION: -

Loading is the task of putting any one of the above

mentioned personality programs (OP/EP/UP) in the

memory of US. After the loading a personality, the US can

serve as the man machine interface with appropriate

functions.

Loading of US is required on the following circumstances:

On initial start up of US.

Power resumption after power failure

 70

Change of personality program is in the US

After resetting the malfunctioning US.

The US is loaded with operator personality in following

steps:

Step 1: A. check US powered ON

B. Adjust the contrast and brightness controls on

VDU panel to the prompt.

C. Check the prompt on the left top of the powered

ON universal station screen.

D. If the prompt is present then go to step 2

Else press RESET button on OKB and wait for

Prompt on US.

Step 2: A. Press LOAD key on OKB

B. Check on the US screen

If N, 1,2,3,4,X? displayed then go to step 3

Else contact the trainer.

Step 3: A. Type N and press ENTER key on OKB.

B. Check on the US screen;

If OPR, ENG, X? displayed then go to step 4

Else contact the trainer.

Step 4: A. Type o and press ENTER key on OKB.

B. Check on the US screen.

 71

If load in progress displayed then go to step 5

Else contact the trainer.

Step 5: wait till CONSOLE STATUS display appears on the

Screen.

After the console status display appears on the US screen,

US takes little more time to settle down with the personality

programs.

UNIVERSAL STATION OPERATIONAL

SECURITY: -
Following operational security is implemented in universal

station: -
 72

Checking each data entry for the right type. Universal

station checks each data entry from keyboard for the

right type required for the operation.

Restricted access to TDC3000 functions and database

like operating parameters, configuration data and

programs.

Following three access levels designed for the restricted

access to TDC3000 database are shown below in figure: -

THREE ACCESS LEVELS ARE GIVEN BELOW: -

Operator level
 73

Supervisor level

Engineer level

Operator level: -permits the user to effectively monitor and

manipulate process parameters during normal operation,

but doesnt permit changes to sensitive process parameters.

Supervisor level: -permits user to alter sensitive process

parameter and permit all the functions allowed at the

operating level.

Engineer level: - permit user to access the entire data base

to perform process and system configuration functions and

programs along with all the functions allowed at the operate

and supervisor level.

Level of access is determined by the

keyboard, key-switch position, access level position is

marked on the key- switch panel.

Following key types enables key-switch positions:

Supervisors key
 74

Engineers key

SUPERVISORS KEY

It enables the access key switch to supervisor level.

ENGINEERS KEY

It enables the access key switch to engineer level. This key

can enable the key switch to supervisor level also.

Without a key, the key switch remains enabled for the

operator level access. The access key can be removed from

the key switch only by bringing the key switch position back

to the operator level.

One more special level of operational security can be

configured called view only.

VIEW ONLY

This level of access allows call up of various displays on US

screen for viewing, but does not permit any data entry.
 75

TDC OPERATOR CONSOLES

The group of universal stations is called an operator

console.

Universal stations are combined to:

Provide the required area and unit specific perception

of the process plant to the operator.

Collect methodical responses from the operator for the

process plant area and unit specific operations.

Printers, floppy /cartridge drives and trend pen recorders

attached to respective us can be shared within an operator

console.
 76

An operator console can contain maximum ten US with or

without respective optional equipment.

USs belonging to one console needs not to be located at the

same place.

Alarm acknowledgement is console wide.

OPERATORS KEY BOARD

The operators keyboard with its key organization is shown

below:
 77

It consists of user configurable function keys& standard

operator function keys.

DESCRIPTION OF STANDARD OPERATOR

FUNCTION KEYS.

It is subdivided into five types of keys:

Standard system displays call & system function keys.

Standard process display call &display control keys.

Standard process alarm management keys.

 78

Standard process operator control keys.

Standard numeric key.

STANDARD SYSTEM DISPLAYS CALL &

SYSTEM FUNCTION KEYS.

 79

SYST STATS: System status key calls up the system

status display on US. The red lamp of the key blinks when

there is an unacknowledged system alarm and remains

steady ON when all console alarms are acknowledged but

not removed.

CONS STATS: Console status key calls up the console

status display on US. The red lamp of the key blinks when

there is an unacknowledged console alarm and remains

steady ON when all the console alarms are acknowledged

but not removed.

 80

RECRD: Trend pen recorder key activates trend pen

recording of selected point on the trend pen recorder. The

red lamp of the key becomes ON while recording is in

progress. Pressing the key again terminates the recording

and lamp switches OFF.

FAST: Fast update key causes the update rate for process
related display information to increase to 2-second interval

instead of the standard update rate of once in 4 seconds.

Red lamp of the key becomes ON when fast update is

selected. Pressing the key again terminates the fast update

and the lamp switches OFF.

CANCL PRINT: cancel print key is used to abort any

currently printing output on any printer in the console.

When pressed, the prompt asks the operator to enter the

console related printer number. Cancel print does not

function across stations with different personalities.

PRINT DISP: print display key is used to print the current

screen display on the assigned printer.
 81

PRINT TREND: print trend key activates trend printing

for the selected point. Trend for all points in an operating

group can be printed on the dot matrix printer.

SYST MENU: system menu display calls up the system

menu display.

LOAD: load key is used to initiate the Universal Station for

personality loading. It works only when the US is not having

any personality loaded in its memory and is in POWER ON

condition.
 82

STANDARD PROCESS DISPLAYS CALL &

DISPLAY CONTROL KEYS

These are the sixteen keys located at the left column of the

standard function keys. The diagram is shown below:

 83

GROUP: Group display key calls up the required group

display on the Universal station screen. A group number is

required to be entered after pressing of the key.

DETAIL: detailed display key calls up the detail display of

required point on the universal station screen. A point ID is

required to be entered after pressing this key.

UNIT TREND: unit trend key calls the unit trend display.
A unit ID is required to be entered after pressing this key.
 84

TREND: trend key calls up the trend of the selected points

on the group display currently shown on the Universal

station.

BATCH: function of this key is deferred.

GOTO: go to key used to select a point on the group

display. A point number (1to8) is required to be entered after

pressing this key.

SCHEM: Schematic key calls up a schematic display on

the universal screen. A schematic name is required to be

entered after pressing this key.

HELP: Help key calls up the pre configured display for

showing required help associated with current display on

the universal station.

DISP SET: not implemented.

 85

HOUR AVG: hourly averages key calls up the hourly

average of process values of the points from the group

display, currently showing on the universal station screen.

PRIOR DISP: prior display key calls up the display that

showing immediately before the current display on the

universal station screen.

ASSOC DISP: associated display key calls up the

configured display associated with the current display on

the universal station screen.

DISP BACK: display back key calls up next lower

numbered display within the same type of display currently

showing on the universal station screen.

 86

DISP FWD: display forward key calls up next higher

numbered display within the same type of display currently

showing on the universal station screen.

PAGE BACK: page back key calls up the next lower

numbered page of a multi page display currently showing

on the universal station screen.

PAGE FWD: page forward key calls up the next higher

numbered page of a multi page display currently showing

on the universal station screen.

 87

PROCESS ALARM MANAGEMENT KEYS:

There are the middle eight keys in lower rows of the

standard function keys. These keys are used for alarm

management. Diagram showing these keys is shown below:

 88

ACK: alarm acknowledges key is used to acknowledge the

process and system alarms for the console. Details of use of

this key will be covered in alarm management.

SIL: silence key is used to silence audible alarms in the

console. Pressing this key dose not ACKNOWLEDGE the

alarms.

MSG SUMM: message summary key calls up the message

summary display on the universal station screen. The red

lamp of the key blinks on the presence of messages that

require operator acknowledgement. Steadily ON lamp

 89

indicates the presences of a message acknowledged but

requires operator confirmation/cancellation.

ALM SUMM: alarm summary key calls up the area alarm

summary display on the universal station screen. The red

and yellow lamps of the key represent different alarm

priorities. On the occurrence of the process alarm the

respective priority lamp blinks for the operator attention &

requires operator acknowledgement.

ALM ANNC: alarm annunciator key calls up the alarm

annunciator display on the universal station screen.

MSG CONFM: message confirmation key is used to

confirm a message currently displayed on the message

summary display.

MSG CLEAR: message clear key is used to clear messages

that have been acknowledged and confirmed on the

message summary display.

 90

UNIT ALM SUMM: unit alarm summary key calls up the

unit alarm summary display. A unit ID is required to be

entered after pressing this key.

STANDARD PROCESS OPERATOR CONTROL

KEYS

These are the right side fifteen keys of the standard

operator function keys. These keys are used to change the

 91

process parameter currently selected on the universal

station display.
 92

MAN: manual mode key used to change the operating

mode of the selected point to manual mode of operation.

AUTO: auto mode key used to change the operating mode

of the selected point to automatic mode of operation.

NORM: normal mode key used to change the operating

mode of the selected point to normally configured mode for

operation.

SP: set point key used to initiate set point value changes of
a point. A value is required to be entered either by numeric

keys or by raise/lower keys after pressing this key.

OUT: output key is used to initiate analog or digital output

value changes of respective points. A value is required to be

entered either by numeric keys or by raise/lower keys after

pressing this key.

SLOW RAISE: slow raise or digital state (ON) change key.

 93

SLOW LOWER: slow lower or digital state (OFF) change

key.

FAST RAISE/FAST LOWER KEY: fast raise /lower

keys are used to fast increment/decrement the selected

value of the point. When the key is pressed fast

increment /decrement in value results every 2/3 of a

second by 2,3,5,10%of the full scale depending on the

system configuration.

CLR ENTRY: clear entry key clears an entry made before

the ENTER key is pressed.

SELECT: select key is used to select an item at the current

cursor position.

TAB KEYS: tab keys are used to position the cursor on

the universal station screen. On pressing these keys cursor

can be moved horizontally left/right or vertically up/down.

If the key is held down the cursor movement is continuous.

 94

STANDARD NUMERIC KEYS

These are the 13 keys centrally located on the standard

operator function keys & are used to enter numeric values.

The numeric keys are shown below:

 95

The ENTER key is pressed to complete the data (numeric as

well as well alphabetic keying) entry.

TOTAL PLANT SOLUTION

The total plant solution TPS system consists of a local

control network& at least one process network. There are

three possible process networks, the Data hiway, the

Universal Control Network (UCN)& the programmable logic

controller (PLC) subsystem.

Each of the process networks has an interface

(called a gateway) that allows it to communicate with the

Local Control Network, which is where TPS work station are

 96

located. The gateway for universal control network interface

is called the network interface module (NIM)& the gateway

for the Programmable Logic Controller subsystem is called

the PLCG.

The process network (Data Hiway, Universal

Control Network, Or Programmable Logic Controller

Subsystem) transmit process data from/to process

connected devices such as controllers & data aquisation

devices (such as temperature, flow & level) through their

gateway to local control network. This makes it possible to

see what is happening at the process without leaving the

workstation, on the local control network. TPS workstation

can be Universal Station Or Global Universal Station (GUS).

Combination of these devices is also possible.

TOTAL PLANT SOLUTION SYSTEM

OVERVIEW
 97

THE MAJOR COMPONENTS OF TPS

SYSTEM ARE: -
 98

UNIVERSAL CONTROL NETWORK (UCN)

The communication channel for the advanced process

manager is called universal control network (UCN) .The UCN

is the platform for processors I/O connections to the TDC

3000.

It is high speed, high accuracy & high

security process control network. It is peer to peer

communication capability allow for easy sharing of process

data making it convenient to implement sophisticated

control schemes.

The UCN features a 5-mega bit per second

Carrier Band Communication System with a token bus

network. It is designed to be compatible with IEEE and ISO

standard. UCN communications are consistent with the

growth and direct of evolving international standards,

appropriate honey well extension for secure process

applications.

The UCN uses redundant coaxial cables and

can support up to 32 redundant devices. The UCN support

peer-to-peer communication for sharing data between

 99

devices on this network & allowing greater coordination of

control strategies. This feature enables sharing information

among advanced process manager, process manager, and

logic manager on the network (UCN process connecting

device) and local control network modules such as history

module, application module and plant network module,

thus offering tremendous power and flexibility in

implementing advance coordinated control strategies.

The UCN is connected to single or multiple

LCNs using network interface module (NIM). Up to 20 UCN

and data Hiway can be connected to the same LCN. At LCN

all of the process data from this process network is available

for the standard TDC3000 operate, control history and

management functions. For example, both UCN & data

Hiway based information can be combined into the sane

group and custom the graphic displays. Or accessed for

history or more advanced control functions as needed.

FUNCTIONAL DESDCRIPTION: -
The universal control network provide a power

communications platform for efficient secure real time

process communication .as a leader in a process

control, HONEYWELL has extensive, expensive with

real time process network

 100

LOCAL CONTROL NETWORK (LCN)

The TPS system consists of many different hardware

modules. These modules are dependent on one another and

require efficient and reliable communication paths between

them. LCN is basically used for man machine interface.

LCN DESCRIPTION

Each of these nodes has a separate address and is

configured to this address through the use of these

jumper plugs (pinning) at the time of installation.

Each of the Hardware Module (nodes) attached to the

LCN have some common functionality, consisting of an

LCN interface mechanism, a processor and memory.

This common functionality is often referred to as the

kernel.

An LCN node takes from when distinct hardware is

added to its Kernel or common logic. A specific

purpose board such as diskette controller, video

generator, special hardware board, etc. bring a

personality with it to the LCN hardware module. In

addition, the node is loaded with a unique software

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package, written specially for that application. The

combination of common hardware, special hardware

and specially designed software combine to form the

nodes specialized personality.

The LCN network consists of two redundant coax

cables that run continuously from node to node (in a

bus topology). Each cable is connected to each nodes

LCN interface circuits with a T-connector. One cable is

marked CABLE A and the other is marked CABLE B.

Both redundant cables are connected to each node.

Each node has specific connection for both A and B

cable and they must not be crossed. Terminators are

used on the ends of both cable A and B. The over all

length of each LCN cable segment should be kept

nearly equal to its redundant companion with a

maximum length of 300 meters and maximum load of

40 physical connections for each LCN cable. Fiber

optics can be used to exceed some limitations.

LCN COMMUNICATION PROTOCOL

The LCN communication Protocol is broadcast type of local

area network. Modules talk(broadcast) on both the A and

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B cables simultaneously, but they listen(receive) on only

one cable. All LCN modules hear all transmission but,

depending on message destination and type, only some

modules process certain messages.

A token passing algorithm is used so that up to 64

modules can share access to the LCN. The communication

master node defines (to other nodes) which cable should be

used for listening. The communication master node is the

Universal Station (US) with the lowest LCN address; it

periodically issues an instruction to switch cables. This

ensures that both cables remain functional.

If any node experiences difficulty in

receiving data on a specific cable, it switches cables and

informs the communication master. The communication

master then informs all the other nodes to switch to the

good cable and dispatches a message to the system

maintenance control center (SMCC) requesting maintenance

on the suspect cable. This allows operation to continue

while the faulty cable is being repaired.

TOKEN PASSING
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Following figures illustrate a sample LCN arrangement

where token passing has been established between several

nodes. The number inside the ring in the figure represents

the node address of the modules on an LCN. Remember, the

ring is imaginary; the physical nodes are really in a

string with the actual node addresses arranged in random

order.

LCN OVERVIEW
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TOKEN PASSING SYSTEM

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AVANCED PROCESS MANAGER (APM)

It is an advanced data acquisition and control device used

for regulatory, logic and sequence control operation required

for continuous or batch applications. It consists of a

redundant advanced process manager module (APMM) and

maximum 40 input out put processors (IOP).

The advanced process manager (APM) is

Honeywell premier TDC 3000 data acquisition and control

device for industrial control applications.

Like the process manager (PM), the advanced

process manager new technology platform offers a range of

capabilities that best meet today and tomorrows process

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requirements. The ASPM offer highly flexible I/O functions

for both data monitoring and control. Power control

functions, including regularity, logic and sequencing control

for provided for continuous, batch or hybrid applications.

An optical toolbox of functions that can be configured and

programmed meets the needs of data acquisition and

advance control requirements in a highly secure and

performance intensive manner. Of course, Amps

capabilities include peer-to-peer communication and

compatibility with industry standard protocols. As seen in

the figure the advanced process manager is a fully

integrated member of the TDC 3000 family.

ACCORDINGLY APM IS CAPABLE OF: -

Performing data acquisition and control functions,

including regularity, logic and sequential control

functions, as well as per to peer communications with

other universal control network-reside4nt devices.

Providing bi-directional communication to modbus and

ALLEN BRADLEY COMPATIBLE subsystems through

a serial interface.
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Fully communicating with operators and engineers at

universal station and universal workstations.

Procedures and displays are identical or similar to

those used with other TDC3000 controllers. Plant

personnel may already be familiar with them.

Supporting higher-level control strategies available on

the Local Control Network through the application

module and host computer.

ADVANCED FEATURES: -

As described above, the Advanced Process Manager (APM)

has the same functionality that of the process manager (PM)

plus:

Digital input sequence of events (DISOE) processing.

Device control points.

Array point for CL programs.

Foreign device (serial) interface capability.

Larger memory (over four times larger than the PM).

String variables.

Time variable.
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FUNCTIONAL DESCRIPTION: -

The advanced process manager is designed to provide

flexible and powerful process scanning and control

capabilities .To do this, it uses advanced multiprocessor

architecture with separate microprocessor dedicated to

perform specific tasks. The APM consist of the advanced

process manager module (APMM) and the I/O subsystem.

The advanced process manger module consists of an

advanced communication processor and modem, advanced

I/O link interface processor and advanced control

processor, a redundant APMM can be optionally provided.

The advanced communication processor is

optimized to provide high performance network

communications. Handling such functions as network data

access and peer-to-peer communication, it also supports

high accuracy time samps.

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NETWORK INTERFACE MODULE (NIM)

The network interface module (NIM) provides the link

between the LOCAL CONTROL NETWORK and the

UNIVERSAL CONTROL NETWORK. Accordingly it makes the

transition from the transmission technique and protocol of

the local control network to the transmission technique and

protocol of the universal control network.

The NIM provides the LCN module access to

data from UCN resident device. It support program and

database loads to the advanced process manager and

forward alarms and message from the network device to the

LCN. The NIM is also available in the redundant

configuration to provide automatic continued operation in

the event of primary failure.

LCN time and UCN time are synchronized by the

NIM. The NIM broadcast LCN time over the UCN. The APM

uses it for all alarms (or events) time stampings.

 110

LOGIC MANAGER (LM)

The logic manager (LM) is a process-connected device that

resides on the TDC 3000 Universal Control Network as a

peer to the process manager. The LM consists of a standard

Honeywell Logic Controller (LC) that contains a two-slot

option module known as Logic Manager Module (LMM) and

is mounted in one or more standard TDC3000 cabinets.

The main features of Logic manager are:

1. Direct peer-to-peer communication with other UCN

devices.

2. Communication with operator, engineer and

maintenance technicians at the universal station.

3. Support of higher-level control strategies through

communication with AM.

4. Database saving and restoration from the HM.

 111

The logic manager (LM) is implemented for the application

requiring fast logic program execution, extensive digital or

interlock logic and ease of ladder programming.

LOGIC MANAGER OVERVIEW: -

 112

As shown in the figure the Honeywell 620 Logic Controller

uses two basic types of racks. These are: -

Processor Rack

I/O Rack

Logic Manger (LM) consists of a Honeywell 620-35 PLC

processor rack with Logic Manager Module (LMM), Parallel

and Serial I/O racks and an MS-DOS Loader Terminal. The

LMM serves as an interface between the 620-35 processor

racks and the UCN. It converts the PLC data into UCN

format and vice versa.

 113

The MS-DOS loader terminal is an IBM compatible PC,

which serves as a man machine interface and is used for

graphic display and ladder programming. The

communication between the PC and processor take place

using an interface board and a serial cabinet shipped with

620-35 PLC.

The LM processor subsystem consists of a

standard Honeywell 620-35 processors rack plus a two slot

optional module known as Logic Manger Module (LMM),

used for UCN connectivity. The subsystem hardware

includes the chassis, back plane, and front plates. The

processor module is vertically positioned in the racks with

the component side towards left. Back plane connector is

offset to prevent inserting a module upside down. The rack

fits into an 8 NEMA 12 enclosure or 19 instrumentation

rack with 14 slots to insert modules.

The LM processor rack has 14 slots from A

to N where different optional or standard modules could be

inserted.

THE DIFFERENT LM PROCESSOR RACKS ARE:

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Processor Module (PM)-slot H

System control Module (SCM)-slot G

Register Module (RM)-slot F

Memory Module slot E

Input/output Control Module (IOCM)-slot I

Power Supply Module (PSM)-slot J&K

Parallel link Drive Module (PLDM)-slot N

Serial Link Module (SLM)-slot L & M

Logic Manger Module (LMM)-slot A &B

Redundancy Control Module (RCM)-slot C

Addition 8Kword Memory Module

REDUNDANCY SYSTEM

The LM redundant control system consists of two identical

configured processors, each containing a redundancy

control module (RCM). One processor is LEAD processor

and the other is the BACKUP processor. The system permit

 115

sharing of data between the two redundant processor by

transferring I/O status cable, register table and system

status table. In the event of failure the control of I/O is

transferred from the LEAD processor to the back up

processor.

REDUNDANCY CONTROL MODULE

It is a primary component of a LM redundancy control

system. It is responsible for:

Transferring I/O status table, Data register table and

system status table information from the LEAD to

BACKUP processor.

Monitoring the status of other RCM and its own host

processor.

Switching the control from LEAD to BACKUP processor

in the event of hardware failure of LEAD processor or

the user request.

SERIAL LINK SELECTOR

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This is general purpose switching device, which may be

used, for connecting MS-DOS loader terminal to the two

processors.

REDUNDANT SIOM

In LM redundant system this module is used instead of

normal SIOM. It has two ports to which the serial I/O

cables coming from the two processors are connected. It

also has the RUN/FREEZE toggle switch. When the switch

is in:

RUN position normal communication between SLM

and serial I/O track is permitted

FREEZE position all real I/O is freezing and

communication between SLM and serial I/O rack is

halted.
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OVERVIEW OF REDUNDANCY SYSTEM

 118

OPERATION OF REDUNDANCY CONTROL

SYSTEM

Consider a LM redundancy processor system with two

processor viz. A and B. suppose initially processor A is in

lead status and processor B is in the backup status. In the

two processor same ladder program is stored and before

every program scan processor A updates the I/O status and

register data in the processor B. thus even though both the

processor share the same program and data but actual

controlling is done by processor A. a backup processor can

be requested to take over the control of the system either

 119

automatically (when lead processor fails) or manually (by

pressing the lead request switch). When the RCM of the

back up processor (in above case it is processor B) grants

the lead request it take following action:

It informs the RCM of processor A that it is taking over

the control of the system.

It commands PBS to transfer all PBS to transfer all

parallel I/O operation to it instead of processor A.

It commands SLS to transfer all serial I/O operation to it

instead of processor A.

Turns on the LEAD status LED on the front plate.

The RCM of the processor A, in turn relinquishes the

control of serial and parallel I/O racks and turns off the

LEAD status LED. Now the processor B act as a lead

processor and processor A act as a backup processor in the

PLC system. Normally the manually lead request is done

while updating the control program. Thus there is no

disturbance in the process operation while a program

upgrading is being done. After the fault is recovered or when

a new program is down loaded the user can again put

processor A in lead position using above method. A step by

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step method of online program down loading making use of

redundancy is as follows:

Consider above LM redundant processor system with two

processor viz. A and B with initially, say processor A in

lead status and processor in backup status and we want

to download a new program in the system. Ensure that

both the processors are online. That is they are either in

RUN or RUN/PROG mode.

Press led request switch on the RCM of processor B and

wait till the LEAD status indicator becomes on. Now

processor B executes the control program and the

program A is backup status.

Put processor A in PROGRAM mode using the mode key

switch on its PLDM.

Connect the MS-DOS loader terminal to processor A and

download the modified ladder program to it.

Put processor A in RUN or RUN/PROG mode using the

mode switch key on its PLDM.

Press led request switch on the RCM of the processor A

and wait till the lead status indicator becomes on. Now
 121

the new control program start execution and the

processor B goes in backup state.

If the new program is not working properly then repeat

steps 2 to 6.

Put processor B in PROGRAM mode so that the new

program gets downloaded in the processor B from A via

data cable. Wait till PORT ACTV indicator on the both

RCMs is on and after that put processor B back in RUN

or RUN/ROG mode.
 122

INDUSTRIAL TRAINING
REPORT
Doing at
GURU HARGOBIND THERMAL PLANT
LEHRA MOHABATT
DISTT. BATHINDA
In
The Partial Fulfillment For The Requirement Of
Award of DEGREE
In
Electronics&communication

SUBMITTED TO:
H.O.D.
ELECTRONICS&COMMUNICATION
S.U.S.C.E.T.TANGORI
MOHALI

SUBMITTED BY:
INDER VERSHA
E.C.E-FINAL YEAR
ROLL NO. 9901744
 123

ACKNOWLEDGEMENT
Industrial training is the effort to provide linkage between the student and Industry in order to develop the
awareness of industrial approach for saving the problem based on broad understanding of tools, modes of
operation of Industrial Organization.
With the deep sense of gratitude, I express my sincere thanks to PSEB,
Patiala, who permitted me to take up training at the Organization. I wish to extend my thanks to Er.
M.S.Thind (S.E./C&I), Er.A.K.Chugh (Add. S.E.), Er.K.K.Jain (Add.S.E)&Er. Chhabra (Add.S.E) for
their considerable help to join the training in different sections of C&I department. I humbly express my
cordial thanks to Mr. Parveen Jain (A.E), Mr.AjitPal Singh (A.E), Mr. Dhiraj Bansal (A.E) and Mr.
S.k.Sharma (A.E) for their extra pain to see me through my problems. They have been always a source of
encouragement and inspiration for me. Under their efficient guidance, I had no problem in acquiring and
getting various jobs done. I am always thankful to staff of industry for their kind cooperation and help,
which made me training a success.
I feel that information gathered by me during this training will surely help me
a lot in coming future.

ABSTRACT

My industrial training of six months of seventh semester of

B.Tech. Electronics&communication
As planned by Punjab technical university is organized in the
Thermal Power Generation Plant at Lehra Mohabbat Distt.
Bathinda.
My training of six months is divided in

three departments of control&instrumentation each

 124

of two months. This report contains overall plant

circuit &department wise description.

INDERVE

RSHA

I
 125

CONTENTS
 126

1. INTRODUCTION
2. WORKING OF THERMAL PLANT
3. SYSTEM DESCRIPTION
4. TDC 3000
5. UNIVERSAL STATION
6. TOTAL PLANT SOLUTION
7. REDUNDANCY SYSTEM

INTRODUCTION

BRIEF HISTORY OF PLANT

PROFILE OF PLANT

POWER DISTRIBUTION
 127

RAW METERIAL &THEIR SOURCES

BASICS OF THERMAL PLANT

RANKINE CYCLE ON TEMPRATURE ENTROPY

DIAGRAM

PROCESS OF POWER GENERATION

PLANT OVERVIEW

BLOCKS DISCRIPTION

VARIOUS CYCLES INVOLVED IN POWER

GENERATION
128
 129

SYSTEM DISCRIPTION

COAL HANDLINGSYSTEM
FUEL OIL SYSTEM
ASH HANDLING SYSTEM
D.M.PLANT
EMERGENCY POWER SUPPLY SYSTEM
CONTROL&INSTRUMENTATION SYSTEM
DATA ACQUISATION SYSTEM
POWER SUPPLY DISTRIBUTION SYSTEM

TDC 3000 SYSTEM

 130

AREA UNIT POINT CONCEPT

DISTRIBUTED CONTROL SYSTEM
FUNTIONS DISTRIBUTED AROUND DCS

BENEFITS OF DCS

TDC ARCHITECTURE

TDC 3000 PROCESS OPERATIONS

 131

UNIVERSAL STATION

DIFFERENT PERIPHERIAL CONNECTED TO U.S.

UNIVERSAL STATION PERSONALITY

LOADING OF U.S

U.S OPERATIONAL SECURITY

TDC OPERATOR CONSOLES

OPERATORS KEYBOARD

DESCRIPTION OF STANDARD OPERATION

FUNTION KEYS
 132

TOTAL PLANT SOLUTION

1. OVERVIEW OF TPS

2. MAJOR COMPONENTS OF TPS

LOCAL CONTROL NETWORK (LCN)

DESCRIPTION

LCN COMMUNICATION PROTOCOL

TOKEN PASSING

OVERVIEW OF LCN

ADVANCE PROCESS MANAGER (APM)

CAPABILITIES OF APM

ADVANCE FEATURES

FUNCTIONAL DESCRIPTION

NETWORK INTERFACE MODULE (NIM)

LOGIC MANAGER (LM)

OVERVIEW OF LM
 133

DIFFERENT LM PROCESSOR RACKS

REDUNDANCY SYSTEM

REDUNDANCY CONTROL MODULE

SERIAL LINK SELECTOR

REDUNDANT SIOM

OVERVIEW OF REDUNDANCY SYSTEM

OPERATION OF REDUNDANCY CONTROL

SYSTEM