NATIONAL THERMAL POWER COOPERATION

BADARPUR THERMAL POWER STATION

NEW DELHI

Submitted by:
Ravi Jain

B.Tech 2nd Year

20085063

Electronics and communication Engineering

MNNIT ALLAHABAD

Duration- 24/05/2010 to 19/06/2010

 ACKNOWLEDGEMENT
I am highly grateful to Proff. SATISH CHANDRA, Training and Placement Department, MNNIT
ALLAHABAD, for providing this opportunity to carry out 4 weeks industrial training at NATIONAL
THERMAL POWER CORPORATION , BADARPUR, NEW DELHI.

I would like to express a deep sense of gratitude and thanks to Mr AJEET KUMAR OJHA-DGM(HR)
without the wise counsel and able guidance, it would have been impossible to complete the report
in this manner.
The help rendered by Mrs RACHANA SINGH BHAL, Sr. Manager, National Thermal Power
Corporation for experimentation is greatly acknowledged.

I would also like to express gratitude to the HOD and other faculty members of department of
Electronics and communication engineering, MNNIT for their intellectual support throughout the
course of this work.

Finally, I would like to thanks Er. SONIA SINGH and all other technical staff of B.T.P.S. for giving
helping me throughout the training period.

Ravi Jain

ECE-MNNIT ALLAHABD

jainscoolravi@gmail.com
 CONTENT
1. INTRODUCTION TO THE COMPANY

2. OPERATION OF POWER PLANT

3. VARIOUS CYCLE AT POWER STATION

4. CONTROL & INSTRUMENTATION

5. IT DEPARTMENT

6. REFERENCE
 About The Company

 Vision

 Strategies

 Environmental Policy

 Evolution
 About The Company
NTPC, the largest power Company in India, was setup in 1975 to accelerate power development in
the country. It is among the world’s largest and most efficient power generation companies. In
Forbes list of World’s 2000 Largest Companies for the year 2007, NTPC occupies 411th place.

A View Of Badarpur Thermal Power Station, New-Delhi

NTPC has installed capacity of 29,394 MW. It has 15 coal based power stations (23,395 MW), 7 gas
based power stations (3,955 MW) and 4 power stations in Joint Ventures (1,794 MW). The
company has power generating facilities in all major regions of the country. It plans to be a 75,000
MW company by 2017.

Types Of Power Station Number Capacity(MW)

Coal Based Power Station 15 23,395
Gas Based Power Station 7 3,955
Joint Venture 4 1,794

Total Capacity – 29,394 MW

NTPC has gone beyond the thermal power generation. It has diversified into hydro power, coal
mining, power equipment manufacturing, oil & gas exploration, power trading & distribution. NTPC
is now in the entire power value chain and is poised to become an Integrated Power Major.
NTPC's share on 31 Mar 2008 in the total installed capacity of the country was 19.1% and it
contributed 28.50% of the total power generation of the country during 2007-08. NTPC has
set new benchmarks for the power industry both in the area of power plant construction and
operations. With its experience and expertise in the power sector, NTPC is extending consultancy
services to various organizations in the power business. It provides consultancy in the area of
power plant constructions and power generation to companies in India and abroad.
In November 2004, NTPC came out with 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 with Government holding 89.5% of the equity share capital and rest held by
Institutional Investors and Public. The issue was a resounding success. NTPC is among the
largest five companies in India in terms of market capitalization.
 Growth Of NTPC Generation & PLF %

Recognizing its excellent performance and vast potential, Government of the India has identified
NTPC as one of the jewels of Public Sector 'Navratnas'- a potential global giant. Inspired by its
glorious past and vibrant present, NTPC is well on its way to realize its vision of being "A world class
integrated power major, powering India's growth, with increasing global presence".
 VISION

Corporate vision: - “A world class integrated power major, powering India's growth
with increasing global presence.”

Mission :-Develop and provide reliable power related products and services at competitive prices,
integrating multiple energy resources with innovative & Eco-friendly technologies and contribution to the
society.

Core Values - BCOMIT

• Business ethics

• Customer Focus

• Organizational & Professional Pride

• Mutual Respect & Trust

• Innovation & Speed

• Total Quality for Excellence

A View Of Well Flourished Plant

 STRATEGIES

Sustainable
Development

Nuturing
Maintain
Human
sector
Resource
Leadership

STRATEGIES

Further
Technology Enchance
Initiatives Fuel Security

Exploit New
Business
Opportunities

Technological Initiatives
 Introduction of steam generators (boilers) of the size of 800 MW.
 Integrated Gasification Combined Cycle (IGCC) Technology.
 Launch of Energy Technology Center -A new initiative for development of technologies with
focus on fundamental R&D.
 The company sets aside up to 0.5% of the profits for R&D.
 Roadmap developed for adopting ‘Clean Development.
 Mechanism’ to help get / earn ‘Certified Emission Reduction.

Corporate Social Responsibility

 As a responsible corporate citizen NTPC has taken up number of CSR initiatives.
 NTPC Foundation formed to address Social issues at national level.
 NTPC has framed Corporate Social Responsibility Guidelines committing up to 0.5% of net
profit annually for Community Welfare Measures on perennial basis.
 The welfare of project affected persons and the local population around NTPC projects are
taken care of through well drawn Rehabilitation and Resettlement policies.
 The company has also taken up distributed generation for remote rural areas.
 ENVIROMANTAL POLICY

NTPC is committed to the environment, generating power at minimal environmental cost and
preserving the ecology in the vicinity of the plants. NTPC has undertaken massive a forestation in
the vicinity of its plants. Plantations have increased forest area and reduced barren land. The
massive a forestation by NTPC in and around its Ramagundam Power station (2600 MW) have
contributed reducing the temperature in the areas by about 3°c. NTPC has also taken proactive
steps for ash utilization. In 1991, it set up Ash Utilization Division

A "Centre for Power Efficiency and Environment Protection- CENPEE" has been established in
NTPC with the assistance of United States Agency for International Development- USAID. CENPEEP
is efficiency oriented, eco-friendly and eco-nurturing initiative - a symbol of NTPC's concern
towards environmental protection and continued commitment to sustainable power development
in India.

As a responsible corporate citizen, NTPC is making constant efforts to improve the socio-economic
status of the people affected by its projects. Through its Rehabilitation and Resettlement
programmes, the company endeavors to improve the overall socio economic status Project
Affected Persons.

NTPC was among the first Public Sector Enterprises to enter into a Memorandum of Understanding-
MOU with the Government in 1987-88. NTPC has been placed under the 'Excellent category' (the
best category) every year since the MOU system became operative.

Harmony between man and environment is the essence of healthy life and growth. Therefore,
maintenance of ecological balance and a pristine environment has been of utmost importance to
NTPC. It has been taking various measures discussed below for mitigation of environment pollution
due to power generation.

NTPC is the second largest owner of trees in the country after the Forest
department.

Environment Policy & Environment Management System

Driven by its commitment for sustainable growth of power, NTPC has evolved a well defined
environment management policy and sound environment practices for minimizing environmental
impact arising out of setting up of power plants and preserving the natural ecology.

NTPC Environment Policy

As early as in November 1995, NTPC brought out a comprehensive document entitled "NTPC
Environment Policy and Environment Management System". Amongst the guiding principles
adopted in the document are company's proactive approach to environment, optimum utilization
of equipment, adoption of latest technologies and continual environment improvement. The policy
also envisages efficient utilization of resources, thereby minimizing waste, maximizing ash
utilization and providing green belt all around the plant for maintaining ecological balance.
Environment Management, Occupational Health and Safety Systems:
NTPC has actively gone for adoption of best international practices on environment, occupational
health and safety areas. The organization has pursued the Environmental Management System
(EMS) ISO 14001 and the Occupational Health and Safety Assessment System OHSAS 18001 at its
different establishments. As a result of pursuing these practices, all NTPC power stations have been
certified for ISO 14001 & OHSAS 18001 by reputed national and international Certifying Agencies.

Pollution Control systems:

While deciding the appropriate technology for its projects, NTPC integrates many environmental
provisions into the plant design. In order to ensure that NTPC comply with all the stipulated
environment norms, various state-of-the-art pollution control systems / devices as discussed below
have been installed to control air and water pollution.

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

Flue Gas Stacks:

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

Low-NOX Burners:
In gas based NTPC power stations, NOx emissions are controlled by provision of Low-NOx Burners
(dry or wet type) and in coal fired stations, by adopting best combustion practices.

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

Coal Settling Pits / Oil Settling Pits:

In these Pits, coal dust and oil are removed from the effluents emanating from the Coal Handling
Plant (CHP), coal yard and Fuel Oil Handling areas before discharge into ETP.

DE & DS Systems:
Dust Extraction (DE) and Dust Suppression (DS) systems have been installed in all coal fired power
stations in NTPC to contain and extract the fugitive dust released in the Coal Handling Plant (CHP).
Cooling Towers:
Cooling Towers have been provided for cooling the hot Condenser cooling water in closed cycle
Condenser Cooling Water (CCW) Systems. This helps in reduction in thermal pollution and
conservation of fresh water.

Ash Dykes & Ash Disposal systems:

Ash ponds have been provided at all coal based stations except Dadri where Dry Ash Disposal
System has been provided. Ash Ponds have been divided into lagoons and provided with garlanding
arrangements for changeover of the ash slurry feed points for even filling of the pond and for
effective settlement of the ash particles.

Ash in slurry form is discharged into the lagoons where ash particles get settled from the slurry and
clear effluent water is discharged from the ash pond. The discharged effluents conform to
standards specified by CPCB and the same is regularly monitored.

At its Dadri Power Station, NTPC has set up a unique system for dry ash collection and disposal
facility with Ash Mound formation. This has been envisaged for the first time in Asia which has
resulted in progressive development of green belt besides far less requirement of land and less
water requirement as compared to the wet ash disposal system.

Ash Water Recycling System:

Further, in a number of NTPC stations, as a proactive measure, Ash Water Recycling System (AWRS)
has been provided. In the AWRS, the effluent from ash pond is circulated back to the station for
further ash sluicing to the ash pond. This helps in savings of fresh water requirements for
transportation of ash from the plant.

The ash water recycling system has already been installed and is in operation at Ramagundam,
Simhadri, Rihand, Talcher Kaniha, Talcher Thermal, Kahalgaon, Korba and Vindhyachal. The scheme
has helped stations to save huge quantity of fresh water required as make-up water for disposal of
ash.

Dry Ash Extraction System (DAES):

Dry ash has much higher utilization potential in ash-based products (such as bricks, aerated
autoclaved concrete blocks, concrete, Portland pozzolana cement, etc.). DAES has been installed at
Unchahar, Dadri, Simhadri, Ramagundam, Singrauli, Kahalgaon, Farakka, Talcher Thermal, Korba,
Vindhyachal, Talcher Kaniha and BTPS.

Liquid Waste Treatment Plants & Management System:

The objective of industrial liquid effluent treatment plant (ETP) is to discharge lesser and cleaner
effluent from the power plants to meet environmental regulations. After primary treatment at the
source of their generation, the effluents are sent to the ETP for further treatment. The composite
liquid effluent treatment plant has been designed to treat all liquid effluents which originate within
the power station e.g. Water Treatment Plant (WTP), Condensate Polishing Unit (CPU) effluent,
Coal Handling Plant (CHP) effluent, floor washings, service water drains etc. The scheme involves
collection of various effluents and their appropriate treatment centrally and re-circulation of the
treated effluent for various plant uses.

NTPC has implemented such systems in a number of its power stations such as Ramagundam,
Simhadri, Kayamkulam, Singrauli, Rihand, Vindhyachal, Korba, Jhanor Gandhar, Faridabad, Farakka,
Kahalgaon and Talcher Kaniha. These plants have helped to control quality and quantity of the
effluents discharged from the stations.

Sewage Treatment Plants & Facilities:

Sewage Treatment Plants (STPs) sewage treatment facilities have been provided at all NTPC
stations to take care of Sewage Effluent from Plant and township areas. In a number of NTPC
projects modern type STPs with Clarifloculators, Mechanical Agitators, sludge drying beds, Gas
Collection Chambers etc have been provided to improve the effluent quality. The effluent quality is
monitored regularly and treated effluent conforming to the prescribed limit is discharged from the
station. At several stations, treated effluents of STPs are being used for horticulture purpose.

Environmental Institutional Set-up:

Realizing the importance of protection of the environment with speedy development of the power
sector, the company has constituted different groups at project, regional and Corporate Centre
level to carry out specific environment related functions. The Environment Management Group,
Ash Utilisation Group and Centre for Power Efficiency & Environment Protection (CENPEEP)
function from the Corporate Centre and initiate measures to mitigate the impact of power project
implementation on the environment and preserve ecology in the vicinity of the projects.
Environment Management and Ash Utilisation Groups established at each station, look after
various environmental issues of the individual station.

Environment Reviews:
To maintain constant vigil on environmental compliance, Environmental Reviews are carried out at
all operating stations and remedial measures have been taken wherever necessary. As a feedback
and follow-up of these Environmental Reviews, a number of retrofit and up-gradation measures
have been undertaken at different stations.

Such periodic Environmental Reviews and extensive monitoring of the facilities carried out at all
stations have helped in compliance with the environmental norms and timely renewal of the Air
and Water Consents.

Waste Management
Various types of wastes such as Municipal or domestic wastes, hazardous wastes, Bio-Medical
wastes get generated in power plant areas, plant hospital and the townships of projects. The
wastes generated are a number of solid and hazardous wastes like used oils & waste oils, grease,
lead acid batteries, other lead bearing wastes (such as garkets etc.), oil & clarifier sludge, used
resin, used photo-chemicals, asbestos packing, e-waste, metal scrap, C&I wastes, electricial scrap,
empty cylinders (refillable), paper, rubber products, canteen (bio-degradable) wastes, buidling
material wastes, silica gel, glass wool, fused lamps & tubes, fire resistant fluids etc. These wastes
fall either under hazardous wastes category or non-hazardous wastes category as per classification
given in Government of India’s notification on Hazardous Wastes (Management and Handling)
Rules 1989 (as amended on 06.01.2000 & 20.05.2003). Handling and management of these wastes
in NTPC stations have been discussed below.
 EVOLUTION

• NTPC was set up in 1975 with 100%

ownership by the Government of
1975 India. In the last 30 years, NTPC has
grown into the largest power utility in
India.

• In 1997, Government of India granted

NTPC status of “Navratna" being one
1997 of the nine jewels of India, enhancing
the powers to the Board of Directors.

• NTPC became a listed company with

majority Government ownership of
2004 89.5%.
• NTPC becomes 3rd largest by Market
Capitalization of listed companies

• The company rechristened as NTPC

Limited in line with its changing
2005 business portfolio and transforms
itself from a thermal power utility to
an integrated power utility.

• National Thermal Power Corporation

is the largest power generation
2008 company in India. Forbes Global 2000
for 2008 ranked it 411th in the world.
OPERATION OF POWER PLANT
 INTRODUCTION

 BASIC PRINCIPLE

 ELECTRICITY FROM COAL

 OPERATION OF BOILER

 OPERATION OF TURBINE
 INTRODUCTION
BADARPUR THERMAL POWER STATION was established on 1973 and it was the part of Central
Government. On 01/04/1978 is was given as No Loss No Profit Plant of NTPC.

Since then operating performance of NTPC has been considerably above the national average. The
availability factor for coal stations has increased from 85.03 % in 1997-98 to 90.09 % in 2006-07,
which compares favourably with international standards. The PLF has increased from 75.2% in
1997-98 to 89.4% during the year 2006-07 which is the highest since the inception of NTPC.

Capacity of BADARPUR THERMAL POWER STATION

Sr. No. Capacity(MW) Number Total Capacity(MW)

1. 210 2 420
2. 95 3 285

Overall Capacity- 705 MW

BASIC PRINCIPLE
As per FARADAY’s Law- “Whenever the amount of magnetic flux linked with a circuit changes, an EMF is
produced in the circuit. Generator works on the principle of producing electricity. To change the flux in the
generator turbine is moved in a great speed with steam.”

To produce steam, water is heated in the boilers by burning the coal. In a Badarpur Thermal Power
Station, steam is produced and used to spin a turbine that operates a generator. Water is heated,
turns into steam and spins a steam turbine which drives an electrical generator. After it passes
through the turbine, the steam is condensed in a condenser; this is known as a Rankine cycle.
Shown here is a diagram of a conventional thermal power plant, which uses coal, oil, or natural gas
as fuel to boil water to produce the steam. The electricity generated at the plant is sent to
consumers through high-voltage power lines The Badarpur Thermal Power Plant has Steam
Turbine-Driven Generators which has a collective capacity of 705MW. The fuel being used is Coal
which is supplied from the Jharia Coal Field in Jharkhand. Water supply is given from the Agra
Canal.
 Electricity from Coal
There are basically three main units of a thermal power plant:
1. Steam Generator or Boiler
2. Steam Turbine
3. Electric Generator

Coupling

Basic Electricity Generation Chart

Functioning of Thermal Power Plant

Typical Diagram of Coal Based Power Plant

Its various parts are listed below:-

1. Cooling tower

2. Cooling water pump

3. Transmission line (3-phase)

4. Unit transformer (3-phase)

5. Electric generator (3-phase)

6. Low pressure turbine

7. Condensate extraction pump

8. Condenser
9. Intermediate pressure turbine

10. Steam governor valve

11. High pressure turbine

12. DE aerator

13. Feed heater

14. Coal conveyor

15. Coal hopper

16. Pulverised fuel mill

17. Boiler drum

18. Ash hopper

19. Super heater

20. Forced draught fan

21. Re heater

22. Air intake

23. Economiser

24. Air preheater

25. Precipitator

26. Induced draught fan

27. Fuel Gas Stack

1. Cooling towers
Cooling Towers are evaporative coolers used for cooling water or other working medium to near the
ambivalent web-bulb air temperature. Cooling tower use evaporation of water to reject heat from
processes such as cooling the circulating water used in oil refineries, Chemical plants, power plants
and building cooling, for example. The tower 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
structure 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 primary use of large , industrial cooling tower system is to remove the heat absorbed in the
circulating cooling water systems used in power plants , petroleum refineries, petrochemical and
chemical plants, natural gas processing plants and other industrial facilities . The absorbed heat is
rejected to the atmosphere by the evaporation of some of the cooling water in mechanical forced-
draft or induced draft towers or in natural draft hyperbolic shaped cooling towers as seen at most
nuclear power plants.

2. Cooling Water Pump

It pumps the water from the cooling tower which goes to the condenser.

3.Three phase transmission line

Three phase electric power is a common method of electric power transmission. It is a type of
polyphase system mainly used to power motors and many other devices. A Three phase system uses
less conductor material to transmit electric power than equivalent single phase, two phase, or direct
current system at the same voltage. In a three phase system, three circuits reach their instantaneous
peak values at different times. Taking one conductor as the reference, the other two current are
delayed in time by one-third and two-third of one cycle of the electrical current. This delay between
“phases” has the effect of giving constant power transfer over each cycle of the current and also
makes it possible to produce a rotating magnetic field in an electric motor.
At the power station, an electric generator converts mechanical power into a set of electric currents,
one from each electromagnetic coil or winding of the generator. The current are sinusoidal functions
of time, all at the same frequency but offset in time to give different phases. In a three phase system
the phases are spaced equally, giving a phase separation of one-third one cycle. Generators output at
a voltage that ranges from hundreds of volts to 30,000 volts.

4. Unit transformer (3-phase)

At the power station, transformers: step-up” this voltage to one more suitable for transmission. After
numerous further conversions in the transmission and distribution network the power is finally
transformed to the standard mains voltage (i.e. the “household” voltage).
The power may already have been split into single phase at this point or it may still be three phase.
Where the step-down is 3 phase, the output of this transformer is usually star connected with the
standard mains voltage being the phase-neutral voltage. Another system commonly seen in North
America is to have a delta connected secondary with a center tap on one of the windings supplying
the ground and neutral. This allows for 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 ( known as a
wild leg) and neutral and 240 V between any two phase) to be available from the same supply.
5. Electrical generator
An Electrical generator is a device that converts kinetic energy to electrical energy, generally using
electromagnetic induction. The task of converting the electrical energy into mechanical energy is
accomplished by using a motor. The source of mechanical energy may be a reciprocating or turbine
steam engine, , water falling through the turbine are made in a variety of sizes ranging from small 1
hp (0.75 kW) units (rare) used as mechanical drives for pumps, compressors and other shaft driven
equipment , to 2,000,000 hp(1,500,000 kW) turbines used to generate electricity. There are several
classifications for modern steam turbines.
Steam turbines are used in all of our major coal fired power stations to drive the generators or
alternators, which produce electricity. The turbines themselves are driven by steam generated in
„Boilers‟ or „steam generators‟ as they are sometimes called.
Electrical power station use large stem turbines driving electric generators to produce most (about
86%) of the world‟s electricity. These centralized stations are of two types: fossil fuel power plants
and nuclear power plants. The turbines used for electric power generation are most often directly
coupled to their-generators .As the generators must rotate at constant synchronous speeds according
to the frequency of the electric power system, the most common speeds are 3000 r/min for 50 Hz
systems, and 3600 r/min for 60 Hz systems. Most large nuclear sets rotate at half those speeds, and
have a 4-pole generator rather than the more common 2-pole one.

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 stage 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 into 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) consist of 4x2 stages. After passing through Intermediate Pressure
Turbine is 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.

7. Condensation Extraction Pump

A Boiler feed water pump is a specific type of pump used to pump water into a steam boiler. The
water may be freshly supplied or retuning condensation of the steam produced by the boiler. These
pumps are normally high pressure units that use suction from a condensate return system and can be
of the centrifugal pump type or positive displacement type.

Construction and operation

Feed water pumps range in size up to many horsepower and the electric motor is usually separated
from the pump body by some form of mechanical coupling. Large industrial condensate pumps may
also serve as the feed water pump. In either case, to force the water into the boiler; the pump must
generate sufficient pressure to overcome the steam pressure developed by the boiler. This is usually
accomplished through the use of a centrifugal pump.
Feed water pumps usually run intermittently and are controlled by a float switch or other similar
level-sensing device energizing the pump when it detects a lowered liquid level in the boiler is
substantially increased. Some pumps contain a two-stage switch. As liquid lowers to the trigger point
of the first stage, the pump is activated. I f the liquid continues to drop (perhaps because the pump
has failed, its supply has been cut off or exhausted, or its discharge is blocked); the second stage will
be triggered. This stage may switch off the boiler equipment (preventing the boiler from running dry
and overheating), trigger an alarm, or both.

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.

9. Intermediate Pressure Turbine

Intermediate Pressure Turbine (IPT) consist of 11 stages. When the steam has been passed through
HPT it gets enter into IPT. IPT has two ends named as FRONT & REAR. Steam enters through front
end and leaves from Rear end.

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 partially opening or closing in response
to signals received from controllers that compares a “set point” to a “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 540°C and at a pressure of
136 kg/cm2. Here it passes through 12 different stages due to which its temperature goes down to
329°C and pressure as 27 kg/cm2. This line is also called as CRH – COLD REHEAT LINE.
It is now passed to an REHEATER where its temperature rises to 540°C and called as HRH-HOT
REHEATED LINE .

12. Deaerator
A Dearator 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 non-corrosive. 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 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 irreversible involved in steam generation and
therefore improves the thermodynamic efficiency of the system.[4] This reduces plant operating
costs and also helps to avoid thermal shock to the boiler metal when the feed water is introduces
back into the steam cycle.
In a steam power (usually modelled as a modified Ranking cycle), feed water heaters allow the feed
water to be brought up to the saturation temperature very gradually. This minimizes the inevitable
irreversibility‟s associated with heat transfer to the working fluid (water). 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.

14. Coal conveyor

Coal conveyors are belts which are used to transfer coal from its storage place to Coal Hopper.

15. Coal Hopper

Coal Hopper are the places which are used to feed coal to Fuel Mill. It also has the arrangement of entering
of Hoy Air at 200°C 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. Pulverised 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 stainless) and its working involves temperatures 390‟C 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 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 and decreasing the likelihood that it will condense inside the engine.
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 so stationary steam engines including power stations.

20. Force Draught Fan

External fans are provided to give sufficient air for combustion. The forced draft fan takes air from
the atmosphere and, first warming it in the air preheater for better combustion, injects it via the air
nozzles on the furnace wall.

21. Reheater
Reheater are heaters which are used to raise the temperature of air which has been fallen down due to
various process.

22. Air Intake

Air is taken from the environment by an air intake tower.

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, and 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 boiler‟s efficiency. They are a device fitted to a boiler which saves
energy by using the exhaust gases from the boiler to preheat the cold water used the 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 Green‟s original design. In this context they are turbines before it
is pumped to the boilers. A common application of economizer is steam power plants is to capture
the waste hit from boiler stack gases (flue gas) and transfer thus it to the boiler feed water thus
lowering the needed energy input , in turn reducing the firing rates to accomplish the rated boiler
output . Economizer lower stack temperatures which may cause condensation of acidic combustion
gases and serious equipment corrosion damage if care is not taken in their design and material
selection.

24. Air Preheater

Air preheater is a general term to describe any device designed to heat air before another process (for
example, combustion in a boiler). The purpose of the air preheater is to recover the heat from the
boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat lost in
the fuel gas. As a consequence, the flue gases are also sent to the flue gas stack (or chimney) at a
lower temperature allowing simplified design of the ducting and the flue gas stack. It also allows
control over the temperature of gases leaving the stack.

25. Precipitator
An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that removes
particles from a flowing gas (such As air) using the force of an induced electrostatic charge.
Electrostatic precipitators are highly efficient filtration devices, and can easily remove fine
particulate matter such as dust and smoke from the air steam.
ESP‟s continue to be excellent devices for control of many industrial particulate emissions, including
smoke from electricity-generating utilities (coal and oil fired), salt cake collection from black liquor
boilers in pump mills, and catalyst collection from fluidized bed catalytic crackers from several
hundred thousand ACFM in the largest coal-fired boiler application.

The original parallel plate-Weighted wire design (described above) has evolved as more efficient (
and robust) discharge electrode designs were developed, today focusing on rigid discharge electrodes
to which many sharpened spikes are attached , maximizing corona production. Transformer –rectifier
systems apply voltages of 50-100 Kilovolts at relatively high current densities. Modern controls
minimize sparking and prevent arcing, avoiding damage to the components. Automatic rapping
systems and hopper evacuation systems remove the collected particulate matter while on line
allowing ESP‟s to stay in operation for years at a time.

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, additionally minimizes erosion of the ID fan.
27. Fuel gas stack
A Fuel gas stack is a type of chimney, a vertical pipe, channel or similar structure through which combustion
product gases called fuel gases are exhausted to the outside air. Fuel gases are produced when coal, oil,
natural gas, wood or any other large combustion device. Fuel gas is usually composed of carbon dioxide
(CO2) and water vapor 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 sulfur 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 aria and thereby reduce the concentration of the pollutants
to the levels required by governmental environmental policies and regulations.
When the fuel gases exhausted from stoves, ovens, fireplaces or other small sources within residential
abodes, restaurants , hotels or other stacks are referred to as chimneys.

OPERATION OF BOILER
The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are
made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter.
Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly
burns, forming a large fireball at the center. The thermal radiation of the fireball heats the water
that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the
boiler is three to four times the throughput and is typically driven by pumps. As the water in the
boiler circulates it absorbs heat and changes into steam at 700 °F (370 °C) and 22.1 MPa. It is
separated from the water inside a drum at the top of the furnace. The saturated steam is
introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as
they exit the furnace. Here the steam is superheated to 1,000 °F (540 °C) to prepare it for the
turbine.
The steam generating boiler has to produce steam at the high purity, pressure and temperature
required for the steam turbine that drives the electrical generator. The generator includes the
economizer, the steam drum, the chemical dosing equipment, and the furnace with its steam
generating tubes and the superheater coils. Necessary safety valves are located at suitable
pointsvto avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft
(FD) fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic
precipitator or baghouse) and the flue gas stack.
 Schematic diagram of a coal-fired power plant steam generator

Boiler Furnace and Steam Drum

Once water inside the boiler or steam generator, the process of adding the latent heat of
vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical
reaction of burning some type of fuel.
The water enters the boiler through a section in the convection pass called the economizer. From
the economizer it passes to the steam drum. Once the water enters the steam drum it goes down
the down comers to the lower inlet water wall headers. From the inlet headers the water rises
through the water walls and is eventually turned into steam due to the heat being generated by the
burners located on the front and rear water walls (typically). As the water is turned into
steam/vapour in the water walls, the steam/vapor once again enters the steam drum.

Fuel Preparation System

In coal-fired power stations, the raw feed coal from the coal storage area is first crushed into small
pieces and then conveyed to the coal feed hoppers at the boilers. The coal is next
pulverized into a very fine powder. The pulverizers may be ball mills, rotating drum grinders, or
other types of grinders.
Some power stations burn fuel oil rather than coal. The oil must kept warm (above its pour
point) in the fuel oil storage tanks to prevent the oil from congealing and becoming un-pumpable.
The oil is usually heated to about 100°C before being pumped through the furnace fuel oil spray
nozzles.

Fuel Firing System and Ignite System

From the pulverized coal bin, coal is blown by hot air through the furnace coal burners at an
angle which imparts a swirling motion to the powdered coal to enhance mixing of the coal
powder with the incoming preheated combustion air and thus to enhance the combustion.
To provide sufficient combustion temperature in the furnace before igniting the powdered coal, the
furnace temperature is raised by first burning some light fuel oil or processed natural gas (by using
auxiliary burners and igniters provide for that purpose).
Air Path
External fans are provided to give sufficient air for combustion. The forced draft fan takes air from
the atmosphere and, first warming it in the air preheater for better combustion, injects it via the air
nozzles on the furnace wall.
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, and additionally minimizes erosion of the ID fan.

Fly Ash Collection

Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag
filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan.
The fly ash is periodically removed from the collection hoppers below the precipitators or bag
filters. Generally, the fly ash is pneumatically transported to storage silos for subsequent transport
by trucks or railroad cars.

Bottom Ash Collection and Disposal

At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from
the bottom of the furnace. This hopper is always filled with water to quench the ash and clinkers
falling down from the furnace. Some arrangement is included to crush the clinkers and for
conveying the crushed clinkers and bottom ash to a storage site.

Boiler Make-up Water Treatment Plant and Storage

Since there is continuous withdrawal of steam and continuous return of condensate to the boiler,
losses due to blow-down and leakages have to be made up for so as to maintain the desired water
level in the boiler steam drum. For this, continuous make-up water is added to the boiler water
system. The impurities in the raw water input to the plant generally consist of calcium and
magnesium salts which impart hardness to the water. Hardness in the make-up water to the boiler
will form deposits on the tube water surfaces which will lead to overheating and failure of the
tubes. Thus, the salts have to be removed from the water and that is done by a water
demineralising treatment plant (DM).

OPERATION OF TURBINE
Steam turbines are used in all of our major coal fired power stations to drive the generators or
alternators, which produce electricity. The turbines themselves are driven by steam generated in
'Boilers' or 'Steam Generators' as they are sometimes called. 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 stage consisting of a stationary blade (or nozzle) and a rotating
blade. Stationary blades convert the potential energy of the steam (temperature and pressure) into
kinetic energy (velocity) and direct the flow onto the rotating blades. The rotating blades convert
the kinetic energy into 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. The
rotational speed is 3000 rpm for Indian System (50 Hz) systems and 3600 for American (60 Hz)
systems.

In a typical larger power stations, the steam turbines are split into three separate stages, the first
being the High Pressure (HP), the second the Intermediate Pressure (IP) and the third the Low
Pressure (LP) stage, where high, intermediate and low describe the pressure of the steam. After
the steam has passed through the HP stage, it is returned to the boiler to be re-heated to its
original temperature although the pressure remains greatly reduced. The reheated steam then
passes through the IP stage and finally to the LP stage of the turbine.
High-pressure oil is injected into the bearings to provide lubrication.
VARIOUS CYCLES AT POWER
STATION
 COAL CYCLE

 CONDENSATE CYCLE

 FEED WATER CYCLE

 STEAM CYCLE
 COAL CYCLE

Coal Stock
Yard

RC Bunker

RC Feeder

Mill

Furnace
 Condensate Cycle

From LP
condensor
Turbine

Condensate
Ejector
Pump

Gland
LPH1
Steam

LPH2 LPH3

Dearrator
 FFED WATER CYCLE

Boiler Feed Boiler

Economizer
Pump Drum

Feed Water Down

HPH5
Line Corner

HPH6 HPH7 Water

 STEAM CYCLE

From Boiler LT Super

Drum Heater

Main Steam
Final Heater
Line

Cold Reheat
HP Turbine
Line

Hot Reheat
Reheater
Line

Low pressure To
Line Condensor
 CONTROL & INSTRUMENTATION
 INTRODUCTION

 C&I LABS

 CONTROL & MONITORING MECHENISM

 PRESSURE MONITORING

 TEMPERATURE MONITORING

 FLOW MEASUREMENT

 CONTROL VALVES
 INTRODUCTION
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
Control and Instrumentation Department has following labs:

1. Manometry Lab
2. Protection and Interlocks Lab
3. Automation Lab
4. Electronics Lab
5. Water Treatment Plant
6. Furnaces Safety Supervisory System Lab

OPERATION AND MAINTAINANCE

Control and Instrumentation Department has following Control Units:

1. Unit Control Board

2. Main Control Board
3. Analog & Digital Signal Control
4. Current Signal Control

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.

A View of Control Room at BTPS

 1. 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
It’s 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

It’s an oval section tube. It’s 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 mind-

1. Accuracy
2. Safety
3. Utility
4. Price

ACCURACY
Higher Accuracy implies Larger Dial Size for accuracy of small and readable pressure scale
increments.

SAFETY
While selecting Pressure Gauge it should consider that Gauge Construction Material should be
chemically compatible with the environment either inside or outside it.

UTILITY
It should keep it mind that range of the Gauge should be according to our need else Overpressure
Failure may occur resulting in damage of Gauge.

PRICE
Lager the Gauge’s Dial size larger would be our price. Better Gauge’s Construction material also
increses the cost. So they must be chosen according to our need.
 2. Protection and Interlock Lab

INTERLOCKING
It is basically interconnecting two or more equipments so that if one equipment 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, which trips the circuit. The main equipments of this lab
are relay and circuit breakers. Some of the instrument uses for protection are:.

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.

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 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.
 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.

1. 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.

2, 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.

3. 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 1100°C 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 is
3000 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

So the Parameters to be monitored are:

1. Speed

2. Temperature

3. Current

4. Voltage

5. Pressure

6. Eccentricity

7. Flow of Gases

8. Vacuum Pressure

9. Valves

10. Level
11. Vibration

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 shown

schematically below.

Typical Bourdon Tube Pressure Gages

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:

In this we use Chromel (Nickel-Chromium Alloy) / Alumel (Nickel-Aluminium Alloy) as two metals.
This is the most commonly used general purpose thermocouple. It is inexpensive and, owing to its
popularity, available in a wide variety of probes. They are available in the−200°C to +1200°C range.
Sensitivity is approximately 41 μV/°C.

RTDs are also used but not in protection systems due to vibrational errors.

We pass a constant current through the RTD. So that if R changes then the Voltage also changes

RTDs used in Industries are Pt100 and Pt1000

Pt100 : 0°C – 100 Ω ( 1 Ω = 2.5 0C )

Pt1000 : 0°C - 1000Ω

Pt1000 is used for higher accuracy.

The gauges used for Temperature measurements are mercury filled Temperature gauges.

For Analog medium thermocouples are used and for Digital medium Switches are used which are
basically mercury switches.
 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
isoccasionally 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), the theoretical pressure drop at the
constriction would be given by (ρ/2)(v22 - v12).
And we know that rate of flow is given by:
Flow = k √ (D.P)
Where DP is Differential Presure 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 :
· PNEUMATIC VALVES – They are air or gas controlled which is compressed to turn or move
them

· HYDRAULIC VALVES – They utilize oil in place of Air as oil has better compression
· MOTORISED VALVES – These valves are controlled by electric motors

FURNACE SAFEGUARD SUPERVISORY SYSTEM

FSSS is also called as Burner Management System (BMS). It is a microprocessor based

programmable logic controller of proven design incorporating all protection facilities required for
such system. Main objective of FSSS is to ensure safety of the boiler.

The 95 MW boilers are indirect type boilers. Fire takes place in front and in rear side. That’s why it’s
called front and rear type boiler.

The 210 MW boilers are direct type boilers (which means that HSD is in direct contact with coal)
firing takes place from the corner. Thus it is also known as corner type boiler.

IGNITER SYSTEM
Igniter system is an automatic system, it takes the charge from 110kv and this spark is brought in
front of the oil guns, which spray aerated HSD on the coal for coal combustion. There is a 5 minute
delay cycle before igniting, this is to evacuate or burn the HSD. This method is known as PURGING.

PRESSURE SWITCH
Pressure switches are the devices that make or break a circuit. When pressure is applied, the switch
under the switch gets pressed which is attached to a relay that makes or break the circuit.

Time delay can also be included in sensing the pressure with the help of pressure valves.
Examples of pressure valves:
1. Manual valves (tap)
2. Motorized valves (actuator) – works on motor action
3. Pneumatic valve (actuator) _ works due to pressure of compressed air
4. Hydraulic valve
 IT DEPARTMENT
 IT BTPS VISION

 IT ROLE & RESPONSIBLITIES @BTPS

 IT APPLICATION @BTPS

 BENEFITS OF IT INNOVATION @ BTPS

 VARIOUS E-SERVICES @BTPS

 SMS ALERT @ BTPS

 REWARDS & RECOGNITION

 BTPS IT VISION
 INTEGRATED IT ENABLEMENT OF BUSINESS PROCESSES FOR EFFICIENT PLANT
MANAGEMENT
 INFORMATION ANYTIME ANYWHERE

IT ROLE & RESPONSIBILITIES @ BTPS

1. Development, Implementation & Support for Local Applications

2. Procurement & Maintenance of IT Infrastructure ( PCs, Printers, Servers & Network LAN,WAN
etc)

3. Support to users for ERP & modules to supplement ERP.

4. Customization & Implementation support for BTPS Applications to other projects.

IT APPLICATION @ BTPS
At BTPS, Information Technology has been used extensively to manage following business
processes-

1. Maintenance Management System

2. Materials Management System
3. Financial Accounting System
4. Contracts Management System
5. Operations & ABT Monitoring System
6. Coal Monitoring & Accounting System
7. Hospital Management System
8. HR, T/S & Training Management System
9. Office Automation & Communication System
10. E-Samadhan complaints monitoring system

Benefits of IT Innovations @ BTPS

1. OPERATIONS
Important & critical parameters of Power Plant operation are monitored online to enable effective
control on operation of various equipments and reduce down time. Online load analysis & Generation
values are monitored to have optimum load balance of various units. Auxiliary power consumption
monitored and controlled. Meritorial operation practicing enabled.

2. MAINTENANCE
Better control over maintenance cost by way of online information available through the system.Based
on failure analysis and equipment history, modified maintenance strategy of Preventive, Predictive and
Risk Based maintenance is implemented. Equipment spares planning are streamlined by way of Annual
 requirement, Vendor wise, linked to Equipment, Standardization of defects and repair codes for easy
filling of Work Order Card, for future analysis.

3. MATERIALS
Material Planning and Procurement system streamlined, resulting in reduction in Administrative lead
Time. Further, procurement on Annual Rate Contract basis enabled through the system, Ordering on
actual need basis (just in time). This further reduces lead time and Inventory carrying.

Detection of duplicate and obsolete items, standardization of material description and specification,
Cleaning and Weeding of redundant data, resulting in overall system improvement and functionalities,
Availability of coal stock status online, reduction in demurrages paid to railways.

4. OFFICE AUTOMATION AND COMMUNICATION

With implementation of e-Desk/e-broadcast, e-alerts, auto mail and BTPS website, information is
available instantly to all and all time, resulting in tremendous reduction in paper communication and
cost.

BTPS IT Applications Highlights

1. Single Login screen, Pass Word & Role based secured access .
2. G.U. Interface, Easy information retrieval/search facility.
3. Information captured once at source.
4. Automation of routine activities.

A View of BTPS Login Page

 ERP/SAP MODULES IMPLEMENTED
(ERP-ENTERPRISE RESOURCES PLANNING)
 Maintenance Management- PM
 Finance Management- FI
 Materials Management- MM
 Human Resource Management- HR
 Operations Management- OPN
 Employee Self Service- ESS

Maintenance Management system, Anurakshan @ BTPS

1. Permit to Work Issue with detailed feedback.
2. Daily Plant Meeting minutes generated online.
3. Trends of defects priority wise /department wise for a period.
4. Equipment history with detailed feedback available.
5. Analysis of repeated equipment failure for corrective action.
6. Standardization of defects & repair codes.
7. Interface with Materials Management System & CMS for WOC cost

MATERIAL & CONTRACT MANAGEMENT SYSTEM (CMS)

1. Initiation and approval of Contract Proposal.
2. Preparation of Tender Documents and approvals.
3. Preparation and processing of Bills.

FINANANCIAL ACCOUNTING SYSTEM (FAS)

1. Status of Income Tax Details, PF slips, Leave, Accrued Interest, and Earning Card available online.
2. Fund Flow Statements & other Reports for day to day functioning.
3. Bank Reconciliation.

Coal Accounting System (CAS)

1. Online uploading of Wagon wise Weight from Wagon Tipplers.
2. Coal and Rail Freight bill payments accounting & reconciliation.
3. Tariff Summary, coal accounting and MIS reports generated from the system.

HOSPITAL MANAGEMENT SYSTEM (HMS)

1. Online patient registration
2. Doctor’s prescription
3. Medicines issues/availability
 4. Investigation reports
5. Annual check-ups, patient history , referrals etc.

A View of Hospital Management System

HR/TRAINING MANAGEMENT SYSTEM

1. Computerized Attendance recording system.
2. Employee database to record/ update information of employees
3. Township/Quarter management system.
4. Performance Management analysis & evaluation system.
 A View of Tanning Management System

VARIOUS E-SERVICES @ BTPS

E-Desk , E-Broadcast,
SMS & E-Mail as Primary
E-SERVICES OFFICE KEY FOCUS AREA
Communication &
AUTOMATION & TOWAREDS PAPERLESS Document Delivery
COMMUNICATION OFFICE System.

SMS ALERT @ BTPS

1. One more IT initiative for fast & convenient way to information sharing thru SMS
2. Automatic SMS alert is already in use for plant load & unit Trip.
3. Send SMS instantly or scheduled date/time.
4. SMS to groups or individual numbers.
 Plant Load & Unit Trip SMS Alert

REWARDS & RECOGNITION

 Badarpur has achieved unique distinction of being; First site in NTPC, with independent
initiative of Development & Implementation of new Oracle based integrated online
Applications, with in house effort. This has been appreciated by NTPC higher management.
 BTPS Received Golden Peacock award for IT Innovation in 2004.

REFERENCE
 TRAINING REPORTS OF PAST YEARS AT NALANDA LIBRARY
 INTERNET
 DOCUMENTS OF IT DEPARTMENT