CONTENT

1. Introduction to the Company

a. About the Company b. Vision c. Strategies d. Evolution

2. Introduction to the Project 3. Project Report

a. Operation
i. Introduction ii. Steam Boiler iii. Steam Turbine iv. Turbine Generator

b. EMD I
i. Switchgear ii. High Tension Switchgear iii. Direct On Line Starter

c. EMD II
i. Generator ii. Protection iii. Transformer

d. C&I
i. MANOMETRY LAB ii. PROTECTION AND INTERLOCK LAB iii. AUTOMATION LAB iv. WATER TREATEMENT LAB v. FURNACE SAFETY SUPERVISORY SYSTEM(FSSS) vi. ELECTRONICS TEST LAB

PROJECT REPORT
OPERATIO N EMD I EMD II C&I

EMD - I
Switchgear High Tension Switchgear Direct On Line Starter

Acknowledgement
With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here. I am extremely grateful to all the technical staff of BTPS/NTPC for their co-operation and guidance that helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me .

& I

Module-II

C&I

MANOMETRY LAB

PROTECTION AND INTERLOCK LAB AUTOMATION LAB WATER TREATEMENT LAB FURNACE SAFETY SUPERVISORY SYSTEM(FSSS) ELECTRONICS TEST LAB

This department is the brain of the plant because from the relays to transmitters followed by the electronic computation chipsets and recorders and lastly the controlling circuitry, all fall under this

MANOMETRY LAB
1. TRANSMITTER

It is used for pressure measurements of gases and liquids, its working principle is that the input pressure is converted into electrostatic capacitance and from there it is conditioned and amplified. It gives an output of 4-20 ma DC. It can be mounted on a pipe or a wall. For liquid or steam measurement transmitters is mounted below main process piping and for gas measurement transmitter is placed above pipe.

2. MANOMETER
Its a tube which is bent, in U shape. It is filled with a liquid. This device corresponds to a difference in pressure across the two limbs.

3. BOURDEN PRESSURE GAUGE

Its an oval section tube. Its one end is fixed. It is provided with a pointer to indicate the pressure on a calibrated scale. It is of 2 types: (a) Spiral type: for Low pressure measurement.

(b) Helical Type: for High pressure measurement.

PROTECTION AND INTERLOCK LAB

1. INTERLOCKING
It is basically interconnecting two or more equipments so that if one equipments fails other one can perform the tasks. This type of interdependence is also created so that equipments connected together are started and shut down in the specific sequence to avoid damage. For protection of equipments tripping are provided for all the equipments. Tripping can be considered as the series of instructions connected through OR GATE. When a fault occurs and any one of the tripping is satisfied a signal is sent to the relay, which trips the circuit. The main equipments of this lab are relay and circuit breakers. Some of the instrument uses for protection are: 1. RELAY It is a protective device. It can detect wrong condition in electrical circuits by constantly measuring the electrical quantities flowing under normal and faulty conditions. Some of the electrical quantities are voltage, current, phase angle and velocity. 2. FUSES It is a short piece of metal inserted in the circuit, which melts when heavy current flows through it and thus breaks the circuit. Usually silver is used as a fuse material because: a) The coefficient of expansion of silver is very small. As a result no critical fatigue occurs and thus the continuous full capacity normal current ratings are assured for the long time. b) The conductivity of the silver is unimpaired by the surges of the current

that produces temperatures just near the melting point. c) Silver fusible elements can be raised from normal operating temperature to vaporization quicker than any other material because of its comparatively low specific heat.

2. MINIATURE CIRCUIT BREAKER

They are used with combination of the control circuits to. a) Enable the staring of plant and distributors. b) Protect the circuit in case of a fault. In consists of current carrying contacts, one movable and other fixed. When a fault occurs the contacts separate and are is stuck between them. There are three types of - MANUAL TRIP - THERMAL TRIP - SHORT CIRCUIT TRIP

3. ROTECTION AND INTERLOCK SYSTEM

1. HIGH TENSION CONTROL CIRCUIT For high tension system the control system are excited by separate D.C supply. For starting the circuit conditions should be in series with the starting coil of the equipment to energize it. Because if even a single condition is not true then system will not start. 2. LOW TENSION CONTROL CIRCUIT For low tension system the control circuits are directly excited from the 0.415 KV A.C supply. The same circuit achieves both excitation and tripping. Hence the tripping coil is provided for emergency tripping if the interconnection fails.

AUTOMATION LAB
This lab deals in automating the existing equipment and feeding routes. Earlier, the old technology dealt with only (DAS) Data Acquisition System and came to be known as primary systems. The modern technology or the secondary systems are coupled with (MIS) Management Information System. But this lab universally applies the pressure measuring instruments as the controlling force. However, the relays are also provided but they are used only for protection and interlocks. Once the measured is common i.e. pressure the control circuits can easily be designed with single chips having multiple applications. Another point is the universality of the supply, the laws of electronic state that it can be any where between 12V and 35V in the plant. All the control instruments are excited by 24V supply (4-20mA) because voltage can be mathematically handled with ease therefore all control systems use voltage system for computation. The latest technology is the use of ETHERNET for control signals.

PYROMETER LAB

(1) LIQUID IN GLASS THERMOMETER Mercury in the glass thermometer

boils at 340 degree Celsius which limits the range of temperature that can be measured. It is L shaped thermometer which is designed to reach all inaccessible places.

(2) ULTRA VIOLET CENSOR This device is used in furnace and it measures the
intensity of ultra violet rays there and according to the wave generated which directly indicates the temperature in the furnace.

(3) THERMOCOUPLES This device is based on SEEBACK and PELTIER effect. It

comprises of two junctions at different temperature. Then the emf is induced in the circuit due to the flow of electrons. This is an important part in the plant.

(4) RTD (RESISTANCE TEMPERATURE DETECTOR ) It performs the

function of thermocouple basically but the difference is of a resistance. In this due to the change in the resistance the temperature difference is measured. In this lab, also the measuring devices can be calibrated in the oil bath or just boiling water (for low range devices) and in small furnace (for high range devices).

FURNACE SAFETY AND SUPERVISORY SYSTEM LAB

This lab has the responsibility of starting fire in the furnace to enable the burning of coal. For first stage coal burners are in the front and rear of the furnace and for the second and third stage corner firing is employed. Unburnt coal is removed using forced draft or induced draft fan. The temperature inside the boiler is 1100 degree Celsius and its height is 18 to 40 m. It is made up of mild steel. An ultra violet sensor is employed in furnace to measure the intensity of ultra violet rays inside the furnace and according to it a signal in the same order of same mV is generated which directly indicates the temperature of the furnace. For firing the furnace a 10 KV spark plug is operated for ten seconds over a spray of diesel fuel and pre-heater air along each of the feeder-mills. The furnace has six feeder mills each separated by warm air pipes fed from forced draft fans. In first stage indirect firing is employed that is feeder mills are not fed directly from coal but are fed from three feeders but are fed from pulverized coalbunkers. The furnace can operate on the minimum feed from three feeders but under not circumstances should any one be left out under operation, to prevent creation of pressure different with in the furnace, which threatens to blast it.

ELECTRONICS LAB

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

ANNUNCIATIN CARDS
They are used to keep any parameter like temperature etc. within limits. It gets a signal if parameter goes beyond limit. It has a switching transistor connected to relay that helps in alerting the UCB.

Control and Instrumentation Control and Instrumentation

Measuring Instrumentsments
In any process the philosophy of instrumentation should

provide a comprehensive intelligence feed back on the important parameters viz. Temperature, Pressure, Level and Flow. This Chapter Seeks to provide a basic understanding of the prevalent instruments used for measuring the above parameters.

Temperature Measurement - The most important parameter in thermal power plant is

temperature and its measurement plays a vital role in safe operation of the plant. Rise of temperature in a substance is due to the resultant increase in molecular activity of the substance on application of heat; which increases the internal energy of the material. Therefore there exists some property of the substance, which changes with its energy content. The change may be observed with substance itself or in a subsidiary system in thermodynamic equilibrium, which is called testing body and the system itself is called the hot body. Expansion Thermometer Solid Rod Thermometers a temperature sensing Controlling device may be designed incorporating in its construction the principle that some metals expand more than others for the same temperature range. Such a device is the thermostat used with water heaters The mercury will occupy a greater fraction of the volume of the container than it will at a low temperature. Under normal atmospheric conditions mercury normally boils at a temperature of (347C). To extend the range of mercury in glass thermometer beyond this point the top end of a thermometer bore opens into a bulb which is many times larger in capacity than the bore. This bulb plus the bore above the mercury, is then filled with nitrogen or carbon dioxide gas at a sufficiently high pressure to prevent boiling at the highest temperature to which the thermometer may be used. Mercury in Steel the range of liquid in glass thermometers although quite large, does not lend itself to all industrial practices. This fact is obvious by the delicate nature of glass also the position of the measuring element is not always the best position to read the result. Types of Hg in Steel Thermometers are: Bourdon Tube Most common and simplest type Spiral type More sensitive and used where compactness is necessary Helical Type Most sensitive and compact. Pointer may be mounted direct on end of helix Which rotates, thus eliminating backlash and lost motion? Linkages, which only allow the pointer to operate over a selected range of pressure to either side of the normal steam pressure. Dewrance Critical Pressure Gauge Measurement of Level Direct Methods 'Sight Glass' is used for local indication on closed or open vessels. A sight glass is a tube of toughened glass connected at both ends through packed unions and vessel. The liquid level will be the same as that in the vessel. Valves are provided for isolation and blow down. "Float with Gauge Post" is normally used to local indication on closed or open vessels. "Float Operated Dial" is used for small tanks and congested areas. The float arm is connected to a quadrant and pinion which rotates the pointer over a scale. Bourden Pressure Gauge a Bourdon pressure gauge calibrated in any fact head is often connected to a tank at or near the datum level. "Mercury Manometer" is used for remote indication of liquid level. The working principle is the same as that of a manometer one limp of a U-tube is connected to the tank, the other being open to atmosphere. The manometer liquid must not mix with the liquid in the vessel, and where the manometer is at

a different level to the vessel, the static head must be allowed in the design of the manometer. 'Diaphragm Type' is used for remote level indication in open tanks or docks etc. A pressure change created by the movement of a diaphragm is proportional to a change in liquid level above the diaphragm. This consists of a cylindrical box with a rubber or plastic diaphragm across its open end as the level increases .the liquid pressure on the diaphragm increases and the air inside is compressed. This pressure is transmitted via a capillary tube to an indicator or recorder incorporating a pressure Measuring element. Sealed Capsule Type The application and principle is the same as for the diaphragm box. In this type, a capsule filled with an inert gas under a slight pressure is exposed to the pressure due to the head of liquid and is connected by a capillary to an indicator. In some cases the capsule is fitted external to the tank and is so arranged that it can be removed whilst the tank is still full, a spring loaded valve automatically shutting off the tapping point. Air Purge System This system provides the simplest means of obtaining an indication of level, or volume, at a reasonable distance and above or below, the liquid being measured. The pressure exerted inside an open ended tube below the surface of a liquid is proportional to the depth of the liquid The Measurement of Flow Two principle measurements are made by flow meters viz. quantity of flow and rate of flow. 'Quantity of flow' is the quantity of fluid passing a given point in a given time, i.e. gallons or pounds. Rate of flow' is the speed of. a fluid passing a given point at a given instant and is proportional to quantity passing at a given instant, i.e. gallons per minute or pounds per hour. There are two groups of measuring devices: Positive, or volumetric, which measure flow by transferring a measured quantity of fluid from the inlet to the outlet. Inferential, which measures the velocity of the flow and the volume passed is inferred, it being equal to the velocity times the cross sectional area of the flow. The inferential type is the most widely used. Measurement of Fluid Flow through Pipes: "The Rotating Impeller Type" is a positive type device which is used for medium quantity flow measurement i.e., petroleum and other commercial liquids. It consists of Two fluted rotors mounted in a liquid tight case fluid flow and transmitted to a counter. Rotating Oscillating Piston Type This is also a positive type device and is used for measuring low and medium quantity flows, e.g. domestic water supplies. This consists of a brass meter body into which is fitted a machined brass working chamber and cover, containing a piston made of ebonite. This piston acts as a moving chamber and transfers a definite volume of fluid from the inlet to the outlet for each cycle. Helical Vane Type For larger rates of flow, a helical vane is mounted centrally in the body of the meter. The helix chamber may be vertical or horizontal and is geared to a counter. Usually of pipe sizes 3" to 10" Typical example is the Kent Torrent Meter. Turbine Type this like the helical Vane type is a inference type of device used for large flows with the minimum of pressure drop. This consists of a turbine or drum revolving in upright bearings, retaining at the top by a collar. Water enters the drum from the top and leaves tangentially casings to rotate at a speed dependent upon the quantity of water passed. The cross sectional area of the meter throughout is equal to the area of the inlet and outlet pipes and is commonly used on direct supply water mains, Combination Meters this is used for widely fluctuating flows. It consists of a larger meter (helical, turbine or fan) in the main with a small rotary meter or suitable type in a bypass. Flow is directed into either the main or bypass according to the quantity of flow

by an automatic valve. By this means flows of 45 to 40,000 gallons per hour can be measured. Measurement of Fluid Flow through Open Channels: The Weir If a fluid is allowed to flow over a square weir of notch, The height of the liquid above the still of the weir, or the bottom of the notch will be a measure of the rate of flow. A formula relates the rate of flow to the height and is dependent upon the design of the Venturi Flumes The head loss caused by the weir flow meter is considerable and its construction is sometimes complicated, therefore the flume is sometimes used. The principle is same as that of venture except that the rate of flow is proportional to the depth of the liquid in the upstream section. It consists of a local contraction in the cross section of flow through a channel in the shape of a venturi. It is only necessary to measure the depth of the upstream section which is a measure of the rate of flow. This may be done by pressure tapping at the datum point or by a float in an adjacent level chamber. Pressure Difference Flow meters These are the most widely used type of flow meter since they are capable of measuring the flow of all industrial fluids passing through pipes. They consists of a primary element inserted in the pipeline which generates a differential pressure, ^he magnitude of which is proportional to the square of the rate of flow and a secondary element which measures this differential pressure and translates it into terms of flow Primary elements Bernoulli's theorem states that the quantity of fluid or gas flowing is proportional to the square root of the differential pressure. There are four principal types of primary elements (or restrictions) as enumerate below: Venturi; This is generally used for medium and high quantity fluid flow and it consists of two hollow truncated cones, the smaller diameters of which are connected together by a short length of parallel pipe, the smallest diameter of the tube formed by this length of parallel pipe is known as the throat section and the lower of the two pressures, (the throat, or downstream pressure) is measured here. Orifice Plate This is the oldest and most common form of pressure differential device. In its simplest form it consists of a thin metal plate with a central hold clamped between two pipe flanges. In the metering of dirty fluids or fluids containing solids the hole is placed so that its lower edge coincides with the inside bottom of the pipe. It is essential that the leading edge of the hole is absolutely sharp rounding or burring would have a very marked effect on the flow