NLC INDIA LIMITED

NAVRATNA-A Government of India Enterprise

NEYVELI-TAMILNADU

CERTIFICATE

This is to certify that the project entitled PLC Designed On-Line

monitoring system for Power transformer protection and control in
THERMAL POWER STATION-II, NLC INDIA Ltd is a bonafide project
submitted by the following students from

ASWIND S (2601131EE111)
GOKULRAJ R (2601131EE131)
GOWTHAM M (2601131EE132)
JOHN JUSTIN S (2601131EE139)
In partial fulfilment of requirement for the award of bachelors degree in
Electrical and Electronics Engineering done during the period 27-12-2016 to
22-01-2017 at TPS-II, Neyveli.

NLC Guide
Shri.N.EZHIL
Chief Manager/O&OS/TPS-II
Permitted to submit the project to college university/authority.

Place: General Manager /EDC

Date: Employee Development Centre,
NLC Ltd, Neyveli.
 DECLARATION

We here by declare that our project work entitled PLC

Designed On-Line monitoring system for Power transformer protection
and control carried out at THERMAL POWER STATION-II,
NEYVELI, submitted to the department of Electrical and Electronics
Engineering in ADHIYAMAAN COLLEGE OF ENGINEERING

for the degree in BE EEE in a reward of work done by us under the

guidance of Shri.EZHIL.

This project report is for reference only and no part of the report will be
published or copied anywhere without the written permission from NLC
Officials.

Date: SIGNATURE
Place: NEYVELI

(ASWIND.S)

(GOKULRAJ.R)

(GOWTHAM.M)

(JOHN JUSTIN.S)
 ACKNOWLEDGEMENT
We would have succeeded in completing our task with the co-operation,
encouragement and help provided to us by various personalities. We want to
thank Electrical operation and operations services division of NEYVELI(7 x
210) MW THERMAL POWER STATION-II, NEYVELI for providing us
the necessary instruments and other resources to deliver our project work.

We also express our thanks to Shri A.MOHAMED DAVOOD/DGM/LD

for providing us the opportunity to carry out project work in NLC Ltd.

We sincerely thank Shri D.VENKATA SUBBAIAH GM/TPS-II for

allowing us to do our project work in TPS-II.

We would like to thank Shri K.PERIYASAMY

DGM/OPERATION/TPS-II,ShriM.SIVAKUMAR DGM/PLANNING &
TECHNICAL for their permission to carry out our project in TPS-II.

With deep sense of gratitude we express our sincere thanks to our

esteemed and worthy training coordinator Shri. KUMAR
CM/MECHANICAL/TRAINING DIVISION who has been a constant source
of inspiration for throughout this project work.

We will be failing in our duties if we do not express our deep sense of

gratitude towards our guide Shri . EZHIL CM/ELECTRICAL
/O&OS for his valuable guidance in carry out this project work under his
effective supervision, encouragement, enlightenment and cooperation.
 We will be failing in our duties if we do not express our deep sense of
gratitude towards Shri K.PRAKASH DCE/ELECTRICAL/O&OS for his
valuable lecture in carry out this project work under his effective supervision,
encouragement, enlightenment and cooperation.

Our greatest thanks to all who wished us success especially our parents.
Above all we render out gratitude to the almighty who bestowed self-confidence
ability and strength in us to complete this work. Our heartfelt thanks to all
colleagues and friends without their help this work would not have been
successful.
 ACKNOWLEDGEMENT

First and foremost, we thank the almighty for giving us the strength and
will power that enabled to make this project successful. Its a great opportunity
to express our sincere thanks to all the people who have contributed to the
successful completion of our project work through their support, encouragement
and guidance.
We have great pleasure of thanking our honourable principal
Dr . N. DURAIPANDIAN, M.E., Ph.D. Velammal Engineering College,
Chennai, for his deserving attitude towards all round development of the
students.
We would also like to immensely thank our Professor and Head of the
Department Dr . D. SRINATH, Ph.D., for giving us the guidance, support and
encouragement to do our project work.
We thank our project coordinators Dr. R. UMAMAHESWAARI, M.E, Ph.D.,
Associate Professor and Mr.M.KARTHIKEYANA ssistant Professor
Department of Electrical and Electronics Engineering for his valuable
suggestion and guidance throughout this project.
Special thanks to our guide Mr. S. GUNASEKAR, M.TECH., Asst
Professor, Department of Electrical and Electronics Engineering for his precious
guidance, support and inspiration during the entire course of our project
We would also like to thank all the other teaching and non-teaching
faculty members who have rendered us their constant support during our
project.
 TABLE OF CONTENT

CHAPTER TITLE PAGE

NO NO

ABSTRACT i
LIST OF FIGURES ii
LIST OF ABBREVATIONS iv
01 NEYVELI LIGNITE CORPORATION 01
1.1 INTRODUCTION 01
1.2 OPERATING UNITS OF THE COMPANY 01
1.2.1 MINE I 02
1.2.2 MINE II 02
1.2.3 MINE IA 03
1.2.4 BARSINGSAR MINE 04
1.2.5 TPS-II 05
1.2.6 AVAILABILITY BASED TARIFF 05

02 THERMAL POWER STATION II 08

2.1 INRODUCTION 08
2.2 GENERAL DESCRIPTION 11
2.3 CURRENT INVOLVEMENT-
GENERATOR TO GRID 11
03 SALIENT FEATURES OF 210MW GENERATORS 14
3.1 INTRODUCTION 14
3.2 STATOR WINDING 15
3.3 STATOR END SHIELD 16
3.4 ROTOR 16
INDUSTRIAL
04 DRIVE CONTROL 17
 4.1
INTRODUCTION 17
4.2 CONTROL
RELAYS 18
4.3 POWER
CONTACTORS 20
4.4 OVERLOAD
PROTECTION
CONTROL 24
4.5 TIMER 24
4.6 TYPES OF
CONTROL LOGIC 25
05 STATOR WATER COOLING SYSTEM 26
5.1 INTRODUCTION 26
5.2 DESCRIPTION 26
5.3 STATOR WATER PUMP 30
5.4 WATER COOLER 30
5.5 STATOR WATER FILTER 31
5.6 MAGENETIC FILTER 31
5.7 EXPANSION TANK 32
5.8 VACUUM PUMP 32
5.9 POLISHING UNIT 33
5.10 GAS TRAP DEVICE 33
5.11 SUPERVISION OF STATOR WATER
COOLING SYSTEM 34
5.12 SWCS CONTROL PANEL 34
5.13 EQUIPMENT MOUNTED IN
CONTROL CABINETS 34
06 DRAWINGS 38
6.1 CIRCUIT DIAGRAM USING
RELAYS AND TIMERS 38
 6.2 SWP-A CONTROL LOGIC USING RELAYS 39
6.3 SWP-B CONTROL LOGIC USING RELAYS 40
6.4 INSTRUMENT FEEDBACK OF SWCS 41
6.5 CONDUCTIVITY ANDFLOW METER FEEDBACK 42
6.6 DRAWBACKS OF TRADITIONAL RELAY LOGIC 43
07 PROGRAMMABLE LOGIC CONTROLLERS 44
7.1 NEED FOR PLC 44
7.2 DEFINITION 46
7.3 BASIC PLC OPERATION 47
7.4 THE FIRST PROGRAMMABLE CONTROLLERS 47
7.5 PLC BASIC PARTS 48
7.6 STRUCTURE OF PLC 48
7.7 CENTRAL PROCESSING UNIT (CPU) 49
7.8 INPUT MODULE 50
7.9 OUTPUT MODULE 51
7.10 SOFTWARE OF PLC 52
7.10.1 LADDER 53
7.10.2 LADDER LOGIC PROGRAMS 55
08 SOFTWARE DEVELOPMENT 57
8.1 BIKE INDICATOR 57
8.2 THREE PHASE MOTOR 58
8.3 SWP-A 59
8.4 SWP-B 60
8.5 INSTRUMENTATION INTEGRATION FOR SWCS 61

09 EXISTING SYSTEM & PROPOSED SYSTEM 66

9.1 DESCRIPTION 66
10 CONCLUSION 70
 ABSTRACT

In the developing countries like India, the primary focus of utility is to

make the units (Generators) available to its maximum and minimizing the
maintenance duration.

The present IEC standards for Electrical Rotating Machines are referred
for testing to establish the performance and quality. However they do not
specify limits or trending of various operating parameters of generator Stator
Water System, which needs to be continuously monitored.

One of the ways of taking away the losses from the windings of any
electrical machines is by direct cooling using water. The optimum design of
large capacity turbo-generator, as a rule envisages water cooling of stator
windings. The 200/210/235 MW generators employ a closed loop circulation of
High quality De-Mineralized water through the stator windings made of
hollow and solid conductors.

The availability of different designs of turbo-generators Stator

Water systems calls for understanding the basic ingredients of the system, their
function and how the system can perform its best. The generator is capable of
delivering its rated load only when the stator-water cooling system is
functioning properly. Therefore it is necessary that highest attention is paid for
proper operation and maintenance.

The paper covers a brief on the Generator Stator Water systems, their
advantages, and design requirements, monitoring of critical parameters along
with permissible associated limits.

Our project titled Generator Cooling System Design will pay

attention on how Stator water cooling system is being carried out using present
control logic, its importance, operation, advantages and limitations in existing
control.
 The direct cooled machine are designed generally, to ensure quick
removal of majority of heat by the water flowing in direct contact of the
winding conductor, in addition to the removal of heat by hydrogen from the
surface of hot winding insulation.

The winding insulation besides having good dielectric strength has

excellent thermal conductivity to ensure fast removal of heat. All strands of the
robel bar are brazed together, at the water box connecting to header. The flexible
connection between the high voltage (e.g. up to 15.75kV) conductors to water
header is through Teflon tube.

We plan to do our project in the above area with Human Machine

Interface based implementation. To enable software control we introduce
Programmable logic controllers. Todays PLC consumes milliseconds of time
for each I/O scanning. It is a real-time operating system. They are playing ever-
popular and critical roles in modern control systems.

By introducing PLC into SWC System the total control is made possible
with software. Incorporation of HMI and PC makes end-user to view system
activities right through desktop screen.

i
 LIST OF FIGURES

FIGURE TITLE PAGE

NO NO

1.1 MINE-I 02
1.2 MINE-II 03
1.3 MINE-IA 04
1.4 BARSINGSAR MINE 04
2.1 THERMAL POWER STATION II 08
4.1 EXAMPLE OF MANUAL CONTROL 16
4.2 EXAMPLE OF AUTOMATIC CONTROL 17
4.3 CONTROL RELAY 17
4.4 POWER CONTACTOR 19
4.5 OVERLOAD RELAY 23
4.6 RELAY AND CONTACTORS 27
4.7 MICROCONTROLLER 27
4.8 PLCS 27
5.1 OVERVIEW OF STATOR WATER COOLING 30
SYSTEM
5.13.1 CONDUCTIVITY METER 35
5.13.2 LEVEL TRANSMITTER 36
5.13.3 FLOW MEASURING SYSTEM 36
5.13.4 WATER PUMP PRESSURE SWITCH 37

6.1 CIRCUIT DIAGRAM USING RELAYS AND

TIMERS 38
6.2 SWP-A CONTROLLER LOGIC USING RELAY 39
6.3 SWP-B CONTROLLER LOGIC USING RELAY 40
6.4 INSTRUMENT FEEDBACK OF SWCS 41
ii
 CONDUCTIVITY
AND FLOW
6.5 METER
FEEDBACK 42
PLC PIN
DIAGRAM OF
7.1 SWCS 46
PLC
CONCEPTUAL
APPLICATION
7.2 DIAGRAM 47
AN EXAMPLE OF
7.3 PLC OPERATION 47
HARDWARE OF
7.4 PLC 49
PLC INPUT
7.5 MODULE LAYOUT 51
LAYOUT OF
7.6 OUTPUT MODULE
INTERFACING 52
NORMALLY OPEN
7.7 INSTRUCTION 53
NORMALLY
CLOSED
7.8 INSTRUCTION 53
OUTPUT
ENERGIZE
7.9 INSTRUCTION 54
7.10 AND LOGIC 54
7.11 OR LOGIC 55
LADDER LOGIC
7.12 PROGRAMS 56
EXISTING
CONTROL
9.1 SCHEME 67
PROPOSED
CONTROL
9.2 SCHEME 68
iii
 LIST OF ABBREVIATIONS

NLC NEYVELI LIGNITE CORPORATION

TPS THERMAL POWER STATION
PLC PROGRAMMABLE LOGIC CONTROLLER
MW MEGA WATT
AC ALTERNATING CURRENT
DC DIRECT CURRENT
GT GENERATING TRANSFORMER
PB PUSH BUTTON
SWCS STATOR WATER COOLING SYSTEM
I CURRENT
V VOLTAGE
R RESISTANCE
VA VOLT AMPERE
OLR OVER LOAD RELAY
PC POWER CONTACTOR
SME SPECIALIZED MINIING EQUIPMENT
SWP STATOR WATER PUMP
CM CONDUCTIVITY METER
NRV NON RETURN VALVE
ETVP EXPANSION TANK VACCUM PUMP
FT FLOW TRANSMITTER
FS FLOW SWITCH
PS PRESSURE SWITCH
iv