Professional Documents
Culture Documents
VOCATIONAL TRAINING AT
Kanti Bijlee Utpadan Nigam Limited .
(A Joint Venture Of NTPC Ltd. & BSEB)
Kanti , Muzaffarpur.
FROM 20/05/2015 TO 06/06/2015
ACKNOWLEDGMENT
I am highly indebted to HOD of C& I Department, all faculty members
of department for providing me an opportunity to have practical
exposure at KBUNL/MTPS Kanti (Joint venture of NTPC Ltd & BSEB)
I express my sincere thanks to A.CHARKBORTY for giving me an
opportunity to take such valuable vacational training in his department.
I also pay my sincere gratitude to Sh.J P Kushwaha (Dy. MGR,C&I) ,
Sh. Anjani Kr Verma (Asst. MGR,C&I), Sh. R N Verma (Asst.
MGR,C&I), Vikas Kumravat(Asst. MGR,C&I) & Vikas Koshta(Asst.
MGR,C&I) for their continuous assistance, guidence and valuable
suggestions .
Last but not the least I am also thankful to Sh. Arun Kr Singh for his
contribution.
My special thanks to HR deptt for faciliating me to impart training at
this project.
ABSTRACT
Any thermal power plant is converting the chemical energy of fossil fuel (coal)
into electrical energy. The process involved for this conversion is based upon the
Modified Rankine Cycle.
The major components that are used to accomplish the modified rankine cycle are
Boiler feed pump,
The steam generator water walls (evaporator),
Steam generator super heaters,
Steam turbine,
Reheater,
Condenser,
Regenerative feed heaters etc.
All components of a power generating cycle are vital and critical in operation. In
Modified Rankin Cycle, the two most important aspects that is added are reheating
& regenerative heating. By reheating we used to send the steam coming from
exhaust of the turbines back to the reheater of the boiler so that its enthalpy
increases and more work can be done by this steam the other purpose is to make
steam dry so that no harm will be done to the blades of the turbine.
In MTPS Kanti, we have three turbines in Tandem coupling namely one H.P
Turbine, one I.P Turbine & one L.P Turbine coupled with the generator to which is
synchronized with the grid to produce electricity at 50Hz.
In all my modesty, I wish to record here that a sincere attempt has been made for
the presentation of this project report. I also trust that this study will not only prove
to be of academic interest but also will be able to provide an insight into the area of
technical management.
INDEX
CONTENT
PAGE NO.
ABOUT NTPC LTD.-------------------------------------------ABOUT KBNUL , KANTI-------------------------------------OPERATION OF POWER PLANT-------------------------PARTS OF POWER PLANT----------------------------------VARIOU CYCLE OCCUR IN POWER PLANT----------ELECTRICAL MAINTENANCE-----------------------------1 MOTOR---------------------------------------------------------------------2.HIGH TENSION/LOW TENSION SWITCHGEAR---------------3. COAL HANDLING PLANT----------------------------------------------4. TRANSFORMER------------------------------------------------------------5. GENERATOR------------------------------------------------------------------6. SWITCH YARD-----------------------------------------------------------------
ABOUT NTPC
India largest power company, NTPC was set up in 1975 to accelerate power
development in India. NTPC is emerging as a diversified power major with
presence in the entire value chain of the power generation business. Apart from
power generation, which is the mainstay of the company, NTPC has already
ventured into consultancy, power trading, ash utilization and coal mining. NTPC
ranked 341st in the 2010, Forbes Global 2000 ranking of the Worlds biggest
companies. NTPC became a Maharatna company in May, 2010, one of the only
four companies to be awarded this status.
The total installed capacity of the company is 39,174 MW (including JVs) with 16
coal based and 7 gas based stations, located across the country. In addition under
JVs, 7 stations are coal based & another station uses naptha/LNG as fuel. The
company has set a target to have an installed power generating capacity of
1,28,000 MW by the year 2032. The capacity will have a diversified fuel mix
comprising 56% coal, 16% Gas, 11% Nuclear and 17% Renewable Energy
Sources(RES) including hydro. By 2032, non-fossil fuel based generation capacity
shall make up nearly 28% of NTPC portfolio.
NTPC has been operating its plants at high efficiency levels. Although the
company has 17.75% of the total national capacity, it contributes 27.40% of total
power generation due to its focus on high efficiency.
In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of
5.25% as fresh issue and 5.25% as offer for sale by Government of India. NTPC
thus became a listed company in November 2004 with the Government holding
89.5% of the equity share capital. In February 2010, the Shareholding of
Government of India was reduced from 89.5% to 84.5% through Further Public
Offer. The rest is held by Institutional Investors and the Public.
Strategies of NTPC
Vision
To be the worlds largest and best power producer,
powering Indias growth.
Mission
Develop and provide reliable power, related products and
services at competitive prices, integrating multiple energy
sources with innovative and eco-friendly technologies and
contribute to society.
D---------------NTPC is the second largest owner of trees in the country after the
Forest department
History
First started in 1985, Kanti Power Plant has an installed capacity of 1102 MW. An
additional capacity of 1952 MW is being erected and is due to be completed by
December 2014.Bihar is the most power stricken state of India; and in the issue of
uplifting our current nation, an excellent and clean 'Thermal Power station' is a
necessity. Kanti thermal Power Plant came into existence in 1985 with the efforts
of then MP of Muzaffarpur,
Operations
To take over Muzaffarpur Thermal Power Station (2*110MW), a subsidiary
company named Vaishali Power Generating Company Limited (VPGCL) with
NTPC on 06/09/2006,-contributing 51% of equity; and the balance equity was
contributed by Bihar State Electricity Board. The company was rechristened as
Kanti Bijlee Utpadan Nigam Limited on April 10, 2008. Present equity holding is
64.57% by NTPC & 35.43% by BSEB. The company is renovating and
modernising the existing unit.The total cost of its renovation and modernization
has been over Rs. 500 Crores.The station has an installed capacity of 2 X 110 MW.
Both the units are under renovation and modernization.An additional capacity of
220MWx2 is being erected and is due to be completed by December 2014.In
March 2013, the renovation work of two old units was completed.MTPS started
commercial production from November 1, 2013 by sypplying 94 MW.This is first
generation in 11 years since 2002.
Sta
ge
Unit
Numb
er
Stage
1
-1
Stage 2
-1
Install
ed
Capac
ity
(MW)
Date of
Commissio
ning
Status
110
1985 March
110
1986 March
Sta
ge
Unit
Numb
er
Install
ed
Capac
ity
(MW)
Date of
Commissio
ning
Status
Stage
3
-2
195
5th May,
2015
Stage 4
-2
195
Under
Construction
Original planned
capacity was 250 MW
Sta
ge
Unit
Numb
er
Install
ed
Capac
ity
(MW)
Date of
Commissio
ning
Status
8. Condenser
1. Cooling Tower
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove
process heat and cool the working fluid to near the wet-bulb air temperature or in
the case of closed circuit dry cooling towers rely solely on air to cool the working
fluid to near the dry-bulb air temperature. Common applications include cooling
the circulating water used in oil refineries, chemical plants, power stations and
building cooling. The towers vary in size from small roof-top units to very large
hyperboloid structures that can be up to 200 meters tall and 100 meters in diameter,
or rectangular structures that can be over 40 meters tall and 80 meters long.
Smaller towers are normally factory-built, while larger ones are constructed on
site. The absorbed heat is rejected to the atmosphere by the evaporation of some of
the cooling water in mechanical forced-draft or inducedDraft towers or in natural
draft hyperbolic shaped cooling towers as seen at most nuclear power plants.
240 V three phase as well as three different single phase voltages( 120 V between
two of the phases and neutral , 208 V between the third phase ( or wild leg) and
neutral and 240 V between any two phase) to be available from the same supply.
6. Low Pressure Turbine Energy in the steam after it leaves the boiler is
converted into rotational energy as it passes through the turbine. The turbine
normally consists of several stages with each stages consisting of a stationary blade
(or nozzle) and a rotating blade. Stationary blades convert the potential energy of
the steam into kinetic energy and direct the flow onto the 24 rotating blades. The
rotating blades convert the kinetic energy into impulse and reaction forces, caused
by pressure drop, which results in the rotation of the turbine shaft. The turbine
shaft is connected to a generator, which produces the electrical energy. Low
Pressure Turbine (LPT) consists of 4x2 stages. After passing through Intermediate
Pressure Turbine steam is passed through LPT which is made up of two parts- LPC
REAR & LPC FRONT. As water gets cooler here it gathers into a HOTWELL
placed in lower parts of turbine.
8. Condenser The steam coming out from the Low Pressure Turbine (a little
above its boiling pump) is brought into thermal contact with cold water (pumped in
from the cooling tower) in the condenser, where it condenses rapidly back into
water, creating near Vacuum-like conditions inside the condenser chest.
10. Steam Governor Valve Steam locomotives and the steam engines used on
ships and stationary applications such as power plants also required feed water
pumps. In this situation, though, the pump was often powered using a small steam
engine that ran using the steam produced by the boiler a means had to be provided,
of course, to put the initial charge of water into the boiler (before steam power was
available to operate the steam-powered feed water pump).The pump was often a
positive displacement pump that had steam valves and cylinders at one end and
feed water cylinders at the other end; no crankshaft was required. In thermal plants,
the primary purpose of surface condenser is to condense the exhaust steam from a
steam turbine to obtain maximum efficiency and also to convert the turbine exhaust
steam into pure water so that it may be reused in the steam generator or boiler as
boiler feed water. By condensing the exhaust steam of a turbine at a pressure below
atmospheric pressure, the steam pressure drop between the inlet and exhaust of the
turbine is increased, which increases the amount heat available for conversion to
mechanical power. Most of the heat liberated due to condensation of the exhaust
steam is carried away by the cooling medium (water or air) used by the surface
condenser. Control valves are valves used within industrial plants and elsewhere to
control operating conditions such as temperature, pressure, flow and liquid level by
fully or partially opening or closing in response to signals received from
controllers that compares a set point to a 26 process variable whose value is
provided by sensors that monitor changes in such conditions. The opening or
closing of control valves is done by means of electrical, hydraulic or pneumatic
systems.
11.High Pressure Turbine Steam coming from Boiler directly feeds into HPT
at a temperature of 540C and at a pressure of 136 kg/cm2. Here it passes through
12 different stages due to which its temperature goes down to 329C and pressure
as 27 kg/cm2. This line is also called as CRH COLD REHEAT LINE. It is now
passed to a REHEATER where its temperature rises to 540C and called as HRHHOT REHEATED LINE.
12. Deaerator A Deaerator is a device for air removal and used to remove
dissolved gases (an alternate would be the use of water treatment chemicals) from
boiler feed water to make it noncorrosive. A dearator typically includes a vertical
domed deaeration section as the deaeration boiler feed water tank. A Steam
generating boiler requires that the circulating steam, condensate, and feed water
should be devoid of dissolved gases, particularly corrosive ones and dissolved or
suspended solids. The gases will give rise to corrosion of the metal. The solids will
deposit on the heating surfaces giving rise to localized heating and tube ruptures
due to overheating. Under some conditions it may give rise to stress corrosion
cracking. Deaerator level and pressure must be controlled by adjusting control
valves the level by regulating condensate flow and the pressure by regulating
steam flow. If operated properly, most deaerator vendors will guarantee that
oxygen in the deaerated water will not exceed 7 ppb by weight (0.005 cm3/L)
13. Feed water heater A Feed water heater is a power plant component used to
pre-heat water delivered to a steam generating boiler. Preheating the feed water
reduces the irreversibility involved in steam generation and therefore improves the
thermodynamic efficiency of the system. This reduces plant operating costs and
also helps to avoid thermal shock to the boiler 27 metal when the feed water is
introduced back into the steam cycle. In a steam power (usually modelled as a
modified Rankine cycle), feed water heaters allow the feed water to be brought up
to the saturation temperature very gradually. This minimizes the inevitable
irreversibility associated with heat transfer to the working fluid (water).
14. Coal conveyor Coal conveyors are belts which are used to transfer coal
from its storage place to Coal Hopper. A belt conveyor consists of two pulleys,
with a continuous loop of material- the conveyor Belt that rotates about them.
The pulleys are powered, moving the belt and the material on the belt forward.
Conveyor belts are extensively used to transport industrial and agricultural
material, such as grain, coal, ores etc.
15. Coal Hopper Coal Hoppers are the places which are used to feed coal to
Fuel Mill. It also has the arrangement of entering Hot Air at 200C inside it which
solves our two purposes:- 1. If our Coal has moisture content then it dries it so that
a proper combustion takes place. 2. It raises the temperature of coal so that its
temperature is more near to its Ignite Temperature so that combustion is easy.
16. Pulverized Fuel Mill A pulveriser is a device for grinding coal for combustion
in a furnace in a fossil fuel power plant.
17. Boiler drum Steam Drums are a regular feature of water tube boilers. It is
reservoir of water/steam at the top end of the water tubes in the water-tube boiler.
They store the steam generated in the water tubes and act as a phase separator for
the steam/water mixture. The difference in densities between hot and cold water
helps in the accumulation of the hotter- water/and saturated steam into steam
drum. Made from high-grade steel (probably 28 stainless) and its working involve
temperature of 390C and pressure well above 350psi (2.4MPa). The separated
steam is drawn out from the top section of the drum. Saturated steam is drawn off
the top of the drum. The steam will re-enter the furnace in through a super heater,
while the saturated water at the bottom of steam drum flows down to the mud-
drum /feed water drum by down comer tubes accessories include a safety valve,
water level indicator and fuse plug.
18. Ash Hopper A steam drum is used in the company of a mud-drum/feed water
drum which is located at a lower level. So that it acts as a sump for the sludge or
sediments which have a tendency to accumulate at the bottom.
19. Super Heater A Super heater is a device in a steam engine that heats the
steam generated by the boiler again increasing its thermal energy. Super heaters
increase the efficiency of the steam engine, and were widely adopted. Steam which
has been superheated is logically known as superheated steam; non- superheated
steam is called saturated steam or wet steam. Super heaters were applied to steam
locomotives in quantity from the early 20th century, to most steam vehicles, and
also stationary steam engines including power stations.
20. Force Draught Fan External fans are provided to give sufficient air for
combustion. The forced draught fan takes air from the atmosphere and, warms it in
the air preheater for better combustion, injects it via the air nozzles on the furnace
wall.
21. Reheater Reheater is a heater which is used to raise the temperature of steam
which has fallen from the intermediate pressure turbine. 29
22. Air Intake Air is taken from the environment by an air intake tower which is
fed to the fuel.
23. Economizers Economizer, or in the UK economizer, are mechanical devices
intended to reduce energy consumption, or to perform another useful function like
preheating a fluid. The term economizer is used for other purposes as well-Boiler,
power plant, heating, ventilating and air-conditioning. In boilers, economizer are
heat exchange devices that heat fluids , usually water, up to but not normally
beyond the boiling point of the fluid. Economizers are so named because they can
make use of the enthalpy and improving the boilers efficiency. They are devices
fitted to a boiler which save energy by using the exhaust gases from the boiler to
preheat the cold water used to fill it (the feed water). Modern day boilers, such as
those in cold fired power stations, are still fitted with economizer which is
decedents of Greens original design. In this context there are turbines before it is
26. Induced Draught Fan The induced draft fan assists the FD fan by drawing out
combustible gases from the furnace, maintaining a slightly negative pressure in the
furnace to avoid backfiring through any opening. At the furnace outlet and before
the furnace gases are handled by the ID fan, fine dust carried by the outlet gases is
removed to avoid atmospheric pollution. This is an environmental limitation
prescribed by law, which additionally minimizes erosion of the ID fan.
27. Flue gas stack A Flue gas stack is a type of chimney, a vertical pipe, channel
or similar structure through which combustion product gases called flue gases are
exhausted to the outside air. Flue gases are produced when coal, oil, natural gas,
wood or any other large combustion 31 device. Flue gas is usually composed of
carbon dioxide (CO2) and water vapour as well as nitrogen and excess oxygen
remaining from the intake combustion air. It also contains a small percentage of
pollutants such as particulates matter, carbon mono oxide, nitrogen oxides and
sulphur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300 feet)
or more, so as to disperse the exhaust pollutants over a greater area and thereby
reduce the concentration of the pollutants to the levels required by government's
environmental policies and regulations. The flue gases are exhausted from stoves,
ovens, fireplaces or other small sources within residential abodes, restaurants,
hotels through other stacks which are referred to as chimneys.
MOTORS
Motors can be classified as AC and DC.
AC MOTORS
(DEGREE CENTIGRADE)
Y
90
105
120
130
155
180
INSTRUMENTS
1. MICROMETER
This instrument is used for measuring inside as well as outside diameter of
bearing.
2. MEGGAR
This instrument is used for measuring insulation resistance.
3. VIBRATION TESTER -- It measures the vibration of the motor. It is
measured in three dimensions-axial, vertical and horizontal.
SWITCH GEAR
INTRODUCTION
Switchgear is one that makes or breaks the electrical circuit. It is a switching
device that opens& closes a circuit that defined as apparatus used for switching,
Lon rolling & protecting the electrical circuit & equipments. The switchgear
equipment is essentially concerned with switching & interrupting currents either
under normal or abnormal operating conditions. The tubular switch with
ordinary fuse is simplest form of switchgear & is used to control & protect&
other equipments in homes, offices etc. For circuits of higher ratings, a High
Rupturing Capacity (H.R.C) fuse in condition with a switch may serve the
purpose of controlling &protecting the circuit. However such switchgear cannot
be used profitably on high voltage system (3.3 KV) for 2 reasons. Firstly, when
a fuse blows, it takes some time to replace it &consequently there is
interruption of service to customer. Secondly, the fuse cannot successfully
interrupt large currents that result from the High Voltage System. In order to
interrupt heavy fault currents, automatic circuit breakers are used. There are
very few types of circuit breakers in B.P.T.S they are VCB, OCB, and SF6 gas
circuit breaker. The most expensive circuit breaker is the SF6 type due to gas.
There are various companies which manufacture these circuit breakers:
VOLTAS, JYOTI, and KIRLOSKAR. Switchgear includes switches, fuses,
circuit breakers, relays & other equipments.
THE EQUIPMENTS THAT NORMALLY FALL IN THIS CATEGORY
ARE:1. ISOLATOR
An isolator is one that can break the electrical circuit when the circuit is to be
switched on no load. These are used in various circuits for isolating the certain
portion when required for maintenance etc. An operating mechanism box
normally installed at ground level drives the isolator. The box has an operating
mechanism in addition to its contactor circuit and auxiliary contacts may be
solenoid operated pneumatic three phase motor or DC motor transmitting
through a spur gear to the torsion shaft of the isolator. Certain interlocks are
also provided with the isolator
These are--1. Isolator cannot operate unless breaker is open
2. Bus 1 and bus 2 isolators cannot be closed simultaneously
3. The interlock can be bypass in the event of closing of bus coupler breaker.
4. No isolator can operate when the corresponding earth switch is on
2. SWITCHING ISOLATOR
Switching isolator is capable of:
1. Interrupting charging current
2. Interrupting transformer magnetizing current
3. Load transformer switching.
Its main application is in connection with the transformer feeder as the unit
makes it possible to switch gear one transformer while the other is still on load.
3.CIRCUIT BREAKER
One which can make or break the circuit on load and even on faults is referred
to as circuit breakers. This equipment is the most important and is heavy duty
equipment mainly utilized for protection of various circuits and operations on
load. Normally circuit breakers installed are accompanied by isolators
4. LOAD BREAK SWITCHES
These are those interrupting devices which can make or break circuits. These
are normally on same circuit, which are backed by circuit breakers
5. EARTH SWITCHES
Devices which are used normally to earth a particular system, to avoid any
accident happening due to induction on account of live adjoining circuits. These
equipments do not handle any appreciable current at all. Apart from this
equipment there are a number of relays etc. which are used in switchgear.
LT SWITCHGEAR
In LT switchgear there is no interlocking. It is classified in following ways:1. MAIN SWITCH
Main switch is control equipment which controls or disconnects the main
supply. The main switch for 3 phase supply is available for the range 32A, 63A,
100A, 200Q, 300A at 500V grade.
2. FUSES
With Avery high generating capacity of the modern power stations extremely
heavy carnets would flow in the fault and the fuse clearing the fault would be
required to withstand extremely heavy stress in process. It is used for supplying
power to auxiliaries with backup fuse protection. With fuses, quick break, quick
make and double break switch fuses for 63A and 100A, switch fuses for
200A,400A, 600A, 800A and 1000A are used.
3. CONTACTORS
AC Contractors are 3 poles suitable for D.O.L Starting of motors and
protecting the connected motors.
4. OVERLOAD RELAY
For overload protection, thermal overload relay are best suited for this purpose.
They operate due to the action of heat generated by passage of current through
relay element.
5. AIR CIRCUIT BREAKERS
It is seen that use of oil in circuit breaker may cause a fire. So in all circuits
breakers at large capacity air at high pressure is used which is maximum at the
time of quick tripping of contacts. This reduces the possibility of sparking. The
pressure may vary from 50-60kg/cm^2 for high and medium capacity circuit
breakers.
CONTACTORS
HT SWITCHGEAR
1. MINIMUM OIL CIRCUIT BREAKER
These use oil as quenching medium. It comprises of simple dead tank row
pursuing projection from it. The moving contracts are carried on an iron arm
lifted by a long insulating tension rod and are closed simultaneously pneumatic
operating mechanism by means of tensions but throw off spring to be provided
at mouth of the control the main current within the controlled device.
Type-HKH 12/1000c
Rated Voltage-66 KV
Normal Current-1250A
Frequency-5Hz
Breaking Capacity-3.4+KA Symmetrical
3.4+KA Asymmetrical
360 MVA Symmetrical
Making Capacity-110 KA
4.VACUUM CIRCUIT BREAKER
It works on the principle that vacuum is used to save the purpose of insulation
and. In regards of insulation and strength, vacuum is superior dielectric medium
and is better that all other medium except air and sulphur which are generally
used at high pressure.
Rated frequency-50 Hz
Rated making Current-10 Peak KA
Rated Voltage-12 KV
Supply Voltage Closing-220 V/DC
GENERATORS
The generator works on the principle of electromagnetic induction. There are
two components stator and rotor. The rotor is the moving part and the stator is
the stationary part. The rotor, which has a field winding, is given a excitation
through a set of 3000rpm to give the required frequency of HZ. The rotor is
cooled by Hydrogen gas, which is locally manufactured by the plant and has
high heat carrying capacity of low density. If oxygen and hydrogen get mixed
then they will form very high explosive and to prevent their combining in any
way there is seal oil system. The stator cooling is done by de-mineralized (DM)
water through hollow conductors. Water is fed by one end by Teflon tube. A
boiler and a turbine are coupled to electric generators. Steam from the boiler is
fed to the turbine through the connecting pipe. Steam drives the turbine rotor.
The turbine rotor drives the generator rotor which turns the electromagnet
within the coil of wire conductors.
Carbon dioxide is provided from the top and oil is provided from bottom to the
generator. With the help of carbon dioxide the oil is drained out to the oil tank.
Hydrogen gas is used to cool down the rotor.
Lube oil is used to cool the bearings.
TRANSFORMERS
INTRODUCTION
It is a static machine which increases or decreases the AC voltage without
changing the frequency of the supply. It is a device that:
Transfer electric power from one circuit to another.
It accomplishes this by electromagnetic induction.
In this the two electric circuits are in mutual inductive influence of each
other
WORKING PRINCIPLE:
It works on FARADAYS LAW OF ELECTROMAGNETIC INDUCTION
(self or mutual induction depending on the type of transformer)
MAIN PARTS:
1.CONSERVATOR
It is used generally to conserve the insulating property of the oil from
deterioration& protect the transformer against failure on account of bad quality of
oil.
STATION TRANSFORMER
It is required to feed power to the auxiliaries during startups. This transformer is
normally rated for initial auxiliary load requirements of the unit in typical cases;
this load is of the order of 60% of the load at full generating capacity. It is provided
with on load tap change to cater to the fluctuating voltage of the grid.
SWITCH YARD
As we know that electrical energy cant be stored like cells, so what we generate
should be consumed instantaneously. But as the load is not constants therefore we
generate electricity according to need i.e. the generation depends upon load. The
yard is the places from where the electricity is send outside. It has both outdoor
and indoor equipments.
OUTDOOR EQUIPMENTS
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
BUS BAR.
LIGHTENING ARRESTER
WAVE TRAP
BREAKER
CAPACITATIVE VOLTAGE TRANSFORMER
EARTHING ROD
CURRENT TRANSFORMER.
POTENTIAL TRANSFORMER
LIGHTENING MASK
INDOOR EQUIPMENTS
i.
ii.
iii.
RELAYS.
CONTROL PANELS
CIRCUIT BREAKERS
BUS BAR
Bus bars generally are of high conductive aluminum conforming to IS-5082 or
copper of adequate cross section .Bus bar located in air insulated enclosures &
segregated from all other components .Bus bar is preferably cover with
polyurethane.
BY PASS BUS
This bus is a backup bus which comes handy when any of the buses become faulty.
When any operation bus has fault, this bus is brought into circuit and then faulty
line is removed there by restoring healthy power line.
LIGHTENING ARRESTOR
It saves the transformer and reactor from over voltage and over currents. It
grounds the overload if there is fault on the line and it prevents the generator
transformer. The practice is to install lightening arrestor at the incoming terminal
of the line. We have to use the lightning arrester both in primary and secondary of
CURRENT TRANSFORMER
It is essentially a step up transformer which step down the current to a known ratio.
It is a type of instrument transformer designed to provide a current in its secondary
winding proportional to the alternating current flowing in its primary.
POTENTIAL TRANSFORMER
It is essentially a step down transformer and it step downs the voltage to a known
ratio.
RELAYS
Relay is a sensing device that makes your circuit ON or OFF. They detect the
abnormal conditions in the electrical circuits by continuously measuring the
electrical quantities, which are different under normal and faulty conditions, like
current, voltage frequency. Having detected the fault the relay operates to complete
the trip circuit, which results in the opening of the circuit breakers and disconnect
the faulty circuit. There are different types of relays:
i.
ii.
iii.
iv.
Current relay
Potential relay
Electromagnetic relay
Numerical relay etc.
In contrast to wet scrubbers which apply energy directly to the flowing fluid
medium, an ESP applies energy only to the particulate matter being collected and
therefore is very efficient in its consumption of energy (in the form of
electricity).The most basic precipitator contains a row of thin vertical wires, and
followed by a stack of large flat metal plates oriented vertically, with the plates
typically spaced about 1 cm to18 cm apart, depending on the application. The air or
gas stream flows horizontally through the spaces between the wires, and then
passes through the stack of plates. A negative voltage of several thousand volts is
applied between wire and plate. If the applied voltage is high enough an electric
(corona) discharge ionizes the gas around the electrodes. Negative ions flow to the
plates and charge the gas-flow particles. The ionized particles, following the
negative electric field created by the power supply, move to the grounded plates.
Particles build up on the collection plates and form a layer. The layer does not
collapse, thanks to electrostatic pressure (given from layer resistivity, electric field,
and current flowing in the collected layer).
This division basically calibrates various instruments and takes care of any faults
occur in any of the auxiliaries in the plant. Instrumentation can be well defined
as a technology of using instruments to measure and control the physical and
chemical properties of a material.
C&I LABS
Manometry Lab.
Protection and Interlocks Lab.
Automation Lab.
Electronics Lab.
Water Treatment Plant.
Furnaces Safety Supervisory System Lab
MANOMETRY LAB
TRANSMITTERS
It is used for pressure measurements of gases and liquids, its working principle is
that the input pressure is converted into electrostatic capacitance and from there it
is conditioned and amplified. It gives an output of 4-20 ma DC. It can be mounted
on a pipe or a wall. For liquid or steam measurement transmitters is mounted
below main process piping and for gas measurement transmitter is placed above
pipe.
MANOMETER
Its a tube which is bent, in U shape. It is filled with a liquid. This device
corresponds to a difference in pressure across the two limbs.
BOURDEN PRESSURE GAUGE
Its an oval section tube. Its one end is fixed. It is provided with a pointer to
indicate the pressure on a calibrated scale. It is of 2 types :
(a) Spiral type: for Low pressure measurement.
(b) Helical Type: for High pressure measurement. While selecting Pressure Gauge
these parameters should keep in mind1. Accuracy
2. Safety
3. Utility
4. Price
ACCURACY
Higher Accuracy implies Larger Dial Size for accuracy of small and readable
pressure scale increments.
SAFETY
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.
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 trips
. I. MANUAL TRIP
II. THERMAL TRIP
III. SHORT CIRCUIT TRIP
Protection and Interlock System1) HIGH TENSION CONTROL CIRCUIT
for high tension system the control system is excited by separate D.C supply. For
starting the circuit conditions should be in series with the starting coil of the
equipment to energize it. Because if even a single condition is not true then system
will not start.
2) LOW TENSION CONTROL CIRCUIT
For low tension system the control circuits are directly excited from the 0.415 KV
A.C supply.
The same circuit achieves both excitation and tripping. Hence the tripping coil is
provided for emergency tripping if the interconnection fails.
3. AUTOMATION LAB
This lab deals in automating the existing equipment and feeding routes. Earlier,
the old technology dealt with only (DAS) Data Acquisition System and came to be
known as primary systems. The modern technology or the secondary systems are
coupled with (MIS) Management Information System. But this lab universally
applies the pressure measuring instruments as the controlling force. However, the
relays are also provided but they are used only for protection and interlocks.
4. PYROMETRY LAB
LIQUID IN GLASS THERMOMETER
Mercury in the glass thermometer boils at 340 C which limits the range of
temperature that can be measured. It is L shaped thermometer which is designed to
reach all inaccessible places.
ULTRA VIOLET SENSOR-This device is used in furnace and it measures the
intensity of ultra violet rays there and according to the wave generated which
directly indicates the temperature in the furnace.
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.
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) .
5. 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
1100C and its heights 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 no circumstances should anyone
be left out under operation, to Prevent creation of pressure different with in the
furnace, which threatens to blast it.
6. 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 & MONITORING MECHANISMS
There are basically two types of Problems faced in a Power Plant
1. Metallurgical
2. Mechanical
Mechanical -Problem can be related to Turbines that is the max speed permissible
for a turbine is3000 rpm so speed should be monitored and maintained at that
level. Metallurgical Problem can be view as the max Inlet Temperature for Turbine
is 1060 C so temperature should be below the limit. Monitoring of all the
parameters is necessary for the safety of both:
1. Employees
2. Machines
PRESSURE MONITORING
Pressure can be monitored by three types of basic mechanisms
1. Switches
2. Gauges
3. Transmitter type
For gauges we use Bourdon tubes. The Bourdon Tube is a non-liquid pressure
measurement device. It is widely used in applications where inexpensive static
pressure measurements are needed. A typical Bourdon tube contains a curved tube
that is open to external pressure input on one end and is coupled mechanically to
an indicating needle on the other end, as shows schematically below.
For Switches pressure switches are used and they can be used for digital means of
monitoring as switch being ON is referred as high and being OFF is as low. All the
monitored data is converted to either Current or Voltage parameter.
The Plant standard for current and voltage are as under
Voltage : 0 10 Volts range
Current : 4 20 milli-Amperes
We use 4mA as the lower value so as to check for disturbances and wire breaks.
Accuracy of such systems is very high.
ACCURACY: 0.1 % Programmable Logic Circuits (PLCs) are used in the
process as they are the heart of Instrumentation
TEMPERATURE MONITORING
We can use Thermocouples or RTDs for temperature monitoring. Normally RTDs
are used for low temperatures. Thermocouple selection depends upon two factors:
1. Temperature Range
2. Accuracy Required
Normally used Thermocouple is K Type Thermocouple:
FLOW MEASUREMENT
Flow measurement does not signify much and is measured just for metering
purposes and for monitoring the processes
ROTAMETERS:
A Rotameter is a device that measures the flow rate of liquid or gas in a closed
tube. It is occasionally misspelled as 'Rotometer'. It belongs to a class of meters
called variable area meters, which measure flow rate by allowing the cross
sectional area the fluid travels through to vary, causing some measurable effect. A
rotameter consists of a tapered tube, typically made of glass, with a float inside that
is pushed up by flow and pulled down by gravity. At a higher flow rate more area
(between the float and the tube) is needed to accommodate the flow, so the float
rises. Floats are made in many different shapes, with spheres and spherical ellipses
being the most common. The float is shaped so that it rotates axially as the fluid
passes. This allows you to tell if the float is stuck since it will only rotate if it is
not.
For Digital measurements Flap system is used.
For Analog measurements we can use the following methods
1. Flow meters
2. Venturimeters / Orifice meters
3. Turbines
4. Mass flow meters (oil level)
5. Ultrasonic Flow meters
6. Magnetic Flow meter (water level )
Selection of flow meter depends upon the purpose, accuracy and liquid to be
measured so different types of meters used.
TURBINE TYPE:
They are simplest of all. They work on the principle that on each rotation of the
turbine a pulse is generated and that pulse is counted to get the flow rate.
VENTURIMETERS :
Referring to the diagram, using Bernoulli's equation in the special case of
incompressible fluids (such as the approximation of a water jet), and the theoretical
pressure drop at the constriction would be given by (/2)(v2 2- v1 2). And we
know that rate of flow is given by: Flow = k (D.P) Where DP is Differential
Pressure or the Pressure Drop.
CONTROL VALVES
A valve is a device that regulates the flow of substances (either gases, fluidized
solids, slurries, or liquids) by opening, closing, or partially obstructing various
passageways. Valves are technically pipe fittings, but usually are discussed
separately. Valves are used in a variety of applications including industrial,
military, commercial, residential, transportation. Plumbing valves are the most
obvious in everyday life, but many more are used.
Some valves are driven by pressure only, they are mainly used for safety purposes
in steam engines and domestic heating or cooking appliances. Others are used in a
controlled way, like in Otto cycle engines driven by a camshaft, where they play a
major role in engine cycle control.
Many valves are controlled manually with a handle attached to the valve stem. If
the handle is turned a quarter of a full turn (90) between operating positions, the
valve is called a quarter-turn valve. Butterfly valves, ball valves, and plug valves
are often quarter-turn valves. Valves can also be controlled by devices called
actuators attached to the stem. They can be electromechanical actuators such as an
electric motor or solenoid, pneumatic actuators which are controlled by air
pressure, or hydraulic actuators which are controlled by the pressure of a liquid
such as oil or water. So there are basically three types of valves that are used in
power industries besides the handle valves.
They are