CONTROL & INSTRUMENTATION

AT
NTPC SINGRAULI

(A VOCATIONAL TRAINING REPORT)

UNDER GUIDENCE OF:-

MR A.R.MAITI
DGM (C&I)

SUBMITTED BY:-
MANISH KUMAR SINGH
A.I.E.T LUCKNOW

1
SINGRUALI SUPER THERMAL POWER STATION, NTPC
Shaktinagar, Sonbhadra (distt.) –U.P.

2
 PREFACE

In today’s world, electricity has an important role to play. People,

today, rely on electricity for the fulfillment of even his basic needs for
comfortable living.

Electricity contributes the largest share to a country’s economic

growth. It is the most powerful resource and has brought industrial
revolution worldwide. It has resulted in social changes too and raised the
standard of living.

In India, several organizations like NHPC, UPSEB, and other state

electricity boards etc. are engaged in electricity generation. NTPC is the
largest among these with an honourable contribution of 28.6 % of India’s
total generated power.

3
 ACKNOWLEDGEMENT

I oblige to acknowledge my heartiest gratitude to all honourable people

who helped me during my vocational training at NTPC Singrauli, Shaktinagar. .

I would like to thank Mr.N.N.SINHA, Sr. Manager, Training Centre, for

granting me the permission for doing my summer vocational training at this
project.

I am also thankful to Mr.NISHITH AGARWAL, Supdt.(C&I) and

Mr.A.K.ANAND, Dy.Supdt.(C&I) for providing the necessary guidance and
training about the Turbine area. I would like to thanks Miss.SADHAVI
SRIVASTAVA, Assistant Engineer (C&I) for giving their valuable guidance
during my training period in the lab area of the control and instrumentation
department.
I would like to thank Mr.ARVIND BHARTI, Dy. Supdt.(C&I) for
providing me the knowledge about the work in the DAS(Data Acquisition
System). I would also thank Mr.J.GHOSH, Dy.Supdt.(C&I) for encouraging and
providing the necessary details in the boiler maintenance. I am also grateful to all
SSTPS staff that helped me directly or indirectly.

I would co-heartedly thank ABU HINA SIDDAQUI, Placement Officer, T

& P Cell, and Mr.S.K MISHRA, HOD(Electronics & Communication Engg.),
A.I.E.T Lucknow for allowing me to do my training at this place.

MANISH KUMAR SINGH

B. Tech. (2007 Batch)
Roll No.-0705330038
Electronics & Communication Engg.
A.I.E.T LUCKNOW.

4
 TABLE OF CONTENTS

1. INTRODUCTION
• NTPC
• NTPC SINGRAULI
• THERMAL POWER PLANT
2. PRINCIPLE OF OPERATION
3. BOILER & AUXILLIARIES
4. TURBINE & AUXILLIARIES
5. GENERATOR & AUXILLIARIES
6. DATA ACQUISITION SYSTEM
7. ELECTROSTATIC PRECIPITATOR
8. AN OVRVIEW OF S.S.T.P.S.

1 . INTRODUCTION
5
 NTPC LIMITED.

NTPC LTD.(A Govt. of India Enterprise) has been the power behind
India’s sustainable power development since November 1975. It is an ISO
9001:2000 certified company.

NTPC was ranked number ONE in the category the “Best Workplace for
large organization” and number EIGHT overall for the year 2008 by Great Places
to Work Institute’s India chapter in collaboration with Economics Times.

The total installed capacity of NTPC, as on 31st Mar’2009, is 30,144 MW

(including 2294 MW from Joint Ventures).

With ambitious growth plan to become a 50,000 MW plus company by

2012 and 75,000 MW plus company by 2017, NTPC — the largest power utility
has already diversified into Hydro (Power) Sector, Coal Mines development and
Exploration & Production of Petroleum.

The Vision of NTPC is:

“A world class integrated power major, powering India’s growth with
increasing global presence.”

And the Core Values of NTPC are:

• Business Ethics
• Customer Focus
• Organizational & Professional Pride
• Mutual Respect and Trust
• Innovation & Speed
• Total Quality for Excellence

Share of NTPC in India’s Total NTPC's contribution in India's

Installed capacity as on 31.03.2009 Total Power Generation
NTPC
27850 MW, 18.79% NTPC,
NTPC 28.60%
NTPC
ALL INDIA ALL ALL INDIA
ALL INDIA INDIA,
148215 MW 71.40%

The above figure shows how NTPC contributed in the vital power requirements of
the country.

6
 NTPC SINGRAULI
(SINGRAULI SUPER THERMAL POWER STATION)

NTPC Singrauli is a coal based Thermal Power Station. It is situated in district of

at. It is a mother plant and hence a flagship Power Station of NTPC.

The detailed description of NTPC Singrauli is as follows:

Capacity : 2000 MW (5*200 + 2*500)
Location : Shaktinagar, Sonbhadra, Uttar Pradesh.
Energy Source : Jayant & Bina Coal Mines of NCL
Water Source : Rehand Dam Reservoir (also known as Govind
Ballabh Pant Sagar)
Beneficiaries : U.P., Uttaranchal, J&K, H.P., Chandigarh,
Rajasthan, Haryana, Punjab, Delhi

THERMAL POWER STATION

Everybody must be having a thought that a thermal power plant is a place

where electricity is produced. But do you know how it is produced?
The chemical energy stored is converted to heat energy which forms the
input of power plant and electrical energy produced by the generator is the output.
Power is the single most important necessity for the common people and
industrial development of a nation. In a convectional power plant the energy is
first converted to a mechanical work and then is converted to electrical energy.
Thus the energy conversions involved are:

The first energy conversion takes in what is called a Boiler or Steam

Generator, the second in a Turbine and the last conversion takes place in the
Generator.

PRINCIPLE OF OPERATION
7
For each process in a vapour power cycle, it is possible to assume a hypothetical
or ideal process which represents the basic intended operation and do not produce
any extraneous effect like heat loss.
1. For steam boiler, this would be a reversible constant pressure heating
process of water to form steam.
2. For turbine, the ideal process would be a reversible adiabatic expansion of
steam.
3. For condenser, it would be a reversible constant pressure heat rejection as
the steam condenser till it becomes saturated liquid.
4. For pump, the ideal process would be the reversible adiabatic compression
of liquid ending at the initial pressure.

When all the above four cycles are combined, the cycle achieved is called
RANKINE CYCLE. Hence the working of a thermal power plant is based upon
Rankine cycle with some modification.

A PULVERIZED COAL FUELED POWER

PLANT
8
A typical pulverized coal fueled power plant is based on Rankine Thermodynamic
cycle. “A Rankine cycle is a vapour cycle that relies on the isentropic expansion
of high pressure gas to produce work”. Let us see a superheat Rankine cycle:

Fig: Super Heat Rankine cycle

9
 Fig: Energy conversion flow diagram.

The basic understanding of the modern thermal power station in terms of major
systems involved can be done under three basic heads viz. generating steam from
coal, conversion of thermal energy to mechanical power and generation & load
dispatch of electric power.
1. Coal to Steam:
 The coal is burnt at the rate up to 282 tonnes per hour (500 MW Unit).
 From track hopper,coal is carried on conveyor belts to bunkers.
 It then falls in to coal pulverizing mill, where it is grounded into
powder as fine as flour.
 Primary air Air is drawn in to the pulverizing mill where it is mixed
with powdered coal.
 The mixture is then carried to the furnace where it mixes with rest of
the air and burns to great heat.
 This heats circulating water and produces steam, which passes to steam
drum at very high pressure.
 The steam is then heated further in the Superheater and fed to high
pressure cylinder of steam turbine.
 The steam is then passed to other cylinders of turbine through reheater.
 The spent steam is sent to condenser, where it turns back to water called
condensate.
 Condensate is sent to lower part of steam drum through feed heater and
economizer.
 The flue gases leaving boiler are used for heating purpose in feed
heater, economizer, and air Preheater.
 The flue gases are then passed to electro-static precipitator and then,
through draught fan, to chimney.

2. Steam to Mechanical Power:

 Steam first enters the high pressure cylinder of turbine where it passes
over a ring of stationary/fixed blades which acts as nozzle and directs
steam onto a ring of moving blades.


10
  Steam passes to the other cylinders through reheater and the process is
repeated again and again.
 This rotates the turbine shaft up to 3000 rpm.
 At each stage, steam expands, pressure decreases and velocity
increases.

3. Mechanical to Electrical Power:

 The shaft is connected to an alternator’s armature.
 Thus the armature is rotated and electric current is produced in the
stator’s windings.
 The generated electricity is of order 25,000 volts.

4. Switching and Transmission:

 Electricity generated is fed to one side of generator’s transformer and
stepped up to 132000, 220000, or 400000 volts.
 It is then passed to a series of three switches an isolator, a circuit
breaker, and another isolator.
 From circuit breaker, current is taken to bus bars and then to another
circuit breaker with its associated isolator before being fed to the main
Grid.
 Each generator has its own switching and transmission arrangement.
 Three-phase system is used for power transmission.

5. Control and instrumentation

Control and Instrumentation (C & I) systems are provided to enable the
power station to be operated in a safe and efficient manner while responding to
the demands of the national grid system. These demands have to be met without
violating the safety or operational constraints of the plants. For example,
metallurgical limitations are important as they set limits on the maximum
permissible boiler metal temperature and the chemical constituents of the Feed
water.
The control and Instrumentation system provides the means of the manual
and automatic control of plant operating conditions to:
 Maintain an adequate margin from the safety and operational
constraints.
 Monitor these margins and the plant conditions, and provide immediate
indications and permanent records.
 Draw the attention of the operator by an alarm system to any
unacceptable reduction in the margins.
 Shut down the plant if the operating constraints are violated.

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TYPES OF INSTRUMENTS :

The different types of instruments normally used are given below:

• Indicators – These are of two categories, namely local and remote.
Local indicators are self-contained and self-operative and are mounted on
the site. The Remote indicators are used for telemeter purposes and
mounted in the centralized control room or control panel. The indicators
are sometimes provided with signaling contacts wherever required. The
Remote indicators depend on electricity, electronics and pneumatic or
hydraulic system for their operation and accordingly they are named. The
indicator can be classified as analogue or digital on the basis of final
display of the reading.
• Recorders – These are necessary wherever the operating history is
required for analyzing the trends and for any future case studies or
efficiency purposes. Recorders can be of single point measuring a single
parameter or multipoint measuring a number of parameters by single
instruments. Multipoint recorders are again categorized as multipoint
continuous or multipoint dot recorders. The multipoint dot recorders select
the point one after the other in a sequence where as the continuous
recorders measure simultaneously all the points.

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 BOILER

DEFINITION:
Boiler is defined as a device that is used to transfer heat energy being
produced by burning of fuel to liquid, generally water, contended in it to cause its
vaporization. Boiler is called “Steam Generator”.
The following are factors essential for the efficient combustion usually
referred as “The three T’s”.
a) Time – It will take a definite time to heat the fuel to its ignition
temperature and having ignited, it will also take time to burn.
b) Temperature – A fuel will not burn until it reaches its ignition
temperature.
c) Turbulence – Turbulence is introduced to achieve a rapid relative
motion between the air and fuel particles.
SPECIFICATIONS:
Following are the specifications of the main boiler used at Singrauli Super
Thermal Power Station for 500 MW Unit:
1. Main Boiler

Type: Forced circulation, Dry bottom,

Tangentially fired, balanced draft, Radiant
Reheat type with direct fired pulverized
coal system.
Manufacturer: BHEL
Designed fuel: Indian Bituminous coal
Furnace type: Fusion welded
Drum:
 Material ~~ Carbon Steel SA—299
 Overall length ~~ 22.07 mtrs.
 Designed pressure ~~ 205 Kg/cm2

13
WATER & STEAM CIRCULATION

fig. – Flow diagram of water & steam circulation

14
STEAM TURBINE
At Singrauli Station, 500 MW capacity turbines are of Kraft Werk Union
(KWU - Germany) design and supplied by BHEL. The turbine is condensing,
tandem compounded, horizontal, reheat type, single shaft machine. It has got
separate high pressure, intermediate and low pressure parts. The HP part is a
cylinder and IP & LP parts are double flow cylinders. The turbine rotor is rigidly
coupled with each other and with generator rotor.

In the 500 MW KWU turbines, single oil is used for lubrication of

bearings, control oil for governing and hydraulic turbine turning gear. During
start-ups, auxiliary oil pump (2 Nos.) supplies the control oil. Once the speed of
the turbine crosses 90% of the rated speed, the main oil pump takes over.

SPECIFICATIONS

Type: The cylindrical reheat condensing turbine having:

 Single flow HP turbine with 18 stages.
 Double flow IP turbine with 14 stages per flow.
 Double flow LP turbine with 6 stages per flow.

Rated Parameters

 Nominal rating : 500 MW

 Peak loading (without HP heaters): : 536.7 MW
 Rated speed : 3000 rpm
 Main steam flow at full load
(with HP heater in service) : 1530 tons per hour
 Main steam pressure /temperature
at full load ~~ : 170 kg/cm2 ,537° C.
 Condenser pressure ~~ : 76 mm Hg
 CW inlet temperature : 28° C.

15
TURBINE GOVERING SYSTEM
In order to maintain the synchronous speed under changing load/grid or
steam conditions, it is equipped with electro-hydraulic governor; fully backed-up
by a hydraulic governor. The measuring and processing of electrical signal offer
the advantages such as flexibility, dynamic stability and simple representation of
complicated functional systems. The integration of electrical and hydraulic system
is an excellent combination with following advantages:
• Exact load frequency drop with high sensitivity.
• Avoids over speeding of turbine during load throw offs.
• Adjustments of drop in fine steps, even during on load operation.
TURBINE PROTECTION SYSTEM
Turbine protection system performs to cover the following functions:-
a. Protection of turbine from inadmissible operating conditions.
b. In case of plant failure, protection against subsequent damages.
c. It restricts occurring failures to minimum.

Standard turbine protection system comprises the following:-

• Mechanical / hydraulic turbine protection.
• Electrical turbine protections.

H.P. - L.P. BY- PASS SYSTEM

The HP By-pass system in coordination with LP By-pass enables boiler
operation and loading independent of the turbine. For matching the live steam and
metal temperature for a quick startup, by-pass stations have been provided, which
dumps the steam to the condenser through pressure reducing station and
desuperheaters, during the period the steam parameters at the boiler are being
raised. This allows quick rising of parameters to a level acceptable to the turbine
for rolling during startup. It helps in quick start of turbine and low noise level,
also economizes the consumption of DM water. Losses of steam into the
atmosphere are cut down to the barest minimum. By-pass system enables to
shorten the start-up time.

16
TURBINE STRESS EVALUATOR
Introduction
During start up, load changes and shut down, the internals of the turbine are
subjected to temperature fluctuations, resulting in thermal stresses.These stresses
cause material fatigue on the turbine components. The main task of the TSE is
On-line monitoring and evaluation of turbine components in respect of their
material fatigue and life expectancy.

Functions of the TSE

• It compares thermal stresses in monitored components with reference
variables.
• TSE influences set point of the turbine speed and load controller.
• Provides three mode- fast, normal and slow.
• On line fatigue rate calculation.
• Long term storage of parameters.
• Determination of optimum load change.
• Influences operation of warm up controller.
• TSC derives start up criteria for ATRS.

TURBOVISORY INSTRUMENT
TURBOVISORY PARAMETERS ARE:
 VIBRATIONS
- SHAFT VIBRATION / ECCENTRICITY
- BEARING VIBRATION
 TURBINE EXPANSION
- OVERALL EXPANSION
- DIFFERENTIAL EXPANSION
- AXIAL SHIFT
 SPEED / OVERSPEED
 LOAD
 TURBINE METAL TEMPERATURE
 VACUUM
 LUB OIL PRESSURE / TEMPERATURE
 HP / LP EXHAUST TEMPERATURE

VIBRATION MEASURING INSTRUMENTATION

 SHAFT VIBRATION / ECCENTRICITY

- PROXIMITY PROBE
 BEARING VIBRATION
- VELOCITY PICK UP

17
Why do we analyse Vibration?
• We can understand the machine
• We can find the weakness
• Thereby we can predict, plan, maintain and improve
• Improve availability and reduce costs

What are the different ways?

• Overall
• Time domain
• Frequency domain
• Envelope analysis
• Cepstrum analysis
• Wavelet analysis
• Etc

Basic Theory
Simple Spring

Upper Limit
Neutral Position

Lower Position 18
 What Is

VIBRATION MONITORING
Modes of Amplitudes :
• DISPLACEMENT
• VELOCITY
• ACCELERATION
• SPIKE ENERGY

Physical Significance Of Vibration Amplitude :

Displacement : Strain Indicator
Velocity : Fatigue Indicator

It is the response of a
Acceleration : Force Indicator
The significance
• Displacement gives the strain energy
• Velocity gives the kinetic energy

system to an internal
• Acceleration gives the force
• Spike energy/HFD/gE are special ways to measure acceleration only.

UNITS OF MEASUREMENT:

external force which

DISPLACEMENT - MICRONS
VELOCITY - MM / SEC.
ACCELERATION - MM / SEC2 , G

causes the system to

AMPLITUDE DESCRIPTORS:
• RMS - (Displacement ,Velocity)
• PEAK - 1.414 RMS (Displacement, Velocity, Acceleration)
• PEAK-TO-PEAK - 2 * PEAK (Displacement)

oscillate.
19
 Accelerom

SIMPLE VIB
Time
Amplitude
(mm)
A

25 July 2009 PMI Revision 0

Period T

Amplitude Freq
20
 REAL VIBR
Time
Amplitude
Accelerometer :
• Uses piezoelectric crystal (mm)
• Normally uses internal amplifier for boosting signal
• It will have low temp application up to 150 degree C
• For high temperature application amplifier is not given inside
• This causes low signal strength and we use gold plated contacts and small
cable lengths (output rated in pc per g). The amplification is done outside
• Normal accelerometer (amplifier inside) will have strong signal output and
can sustain cable lengths of 300 meter
• Available in several design, can go from DC to 10k Hz freq (600,000 CPM)
• Can measure Acceleration, velocity and displacement
• It is advised to involve suppliers or persons knowledgeable in this area to
choose accelerometers for on line monitoring applications Frequenc
Amplitude
(mm)

Velocity
Output=B*l*V
25 July 2009 B & l are constant PMI Revisi

Output is proportional to velocity, hence

21
Velocity sensor :
• This is self generating (764 mv per mm/sec)
• Can sustain cable length of 1000 feet easily
• For longer length intermediate amplification is needed
• The temperature rating is higher up to 250 degree C (no electronics inside)
• Sensitive to 60,000 CPM
• Can check velocity and displacement only

PROXIMITY SE
Eddy C

CONDUCTIVE
MATERIAL

Radio Freq
Signal

OBSERVED EXTENSION CABLE

MATERIAL
AND PROBE

22
 THE PROXIMIT
Eddy Curr

CONDUCTIVE
MATERIAL

Radio Freq
Signal
PROXIMITY SEN
The oscillator in the matching unit su
The matching unit converts the se
with a load Independent,high frequen
proportional to the distance betwe
brought near to a metal object,the e
the object and the power is absorbe
the coil.The alternating voltage is pr
measured Object1 and the sensor.
2
independent D.C. Voltage ~
~signal.
~
~~
23
CONDENSATE EXTRACTION PUMP (CEP)

The condensate extraction

pump (CEP) is a centrifugal
type vertical pump,
consisting of pump body,
can, distributor housing and
the driven lantern.
The steam after
condensing in the condensing in the condenser known as condensate is extracted
out of the condenser hot well by condensate pump and taken to the Deaerator
through ejectors, gland steam cooler and series of LP heaters. The function of
these pumps is to pump out the condensate. These pumps have four stages and
since the suction is at a negative pressure, special arrangements have been made
for providing sealing.

BOILER FEED PUMP (BFP)

24
 The Weir type
FK8D30 pressure
stage pump is an 8
stage horizontal
centrifugal
pump.This system
plays an important
role in supply of feed
water to the boiler at
requisite pressure
and steam/water
ratio.
This pump is
horizontal and of
barrel design driven
by an electric motor
through a hydraulic
coupling.
The water
with the given
operating
temperature should
flow continuously to the pump under a certain minimum pressure. It passes
through the suction branch into the intake spiral. After leaving first impeller it
passes through the distributing passages of the diffuser and thereby gets a certain
pressure rise. Thus the feed water reaching into discharge space develops the
necessary operating pressure.

Each BFP is provided with a Booster pump in its suction line, which is
driven by the main motor of the boiler feed pump. One of the major damages that
may occur to a BFP is from Cavitation or vapor bounding at the pump suction due
to suction failure. Cavitation will occur when the suction pressure of the pump at
the pump suction is equal or very near to the vapor pressure.

Deaerator
25
A steam generating boiler requires that the boiler feed water should be devoid of
air and other dissolved gases, particularly corrosive ones, in order to avoid
corrosion of the metal.

Generally, power stations use a deaerator to provide for the removal of air and
other dissolved gases from the boiler feedwater. A deaerator typically includes a
vertical, domed deaeration section mounted on top of a horizontal cylindrical
vessel which serves as the deaerated boiler feedwater storage tank.

GENERATOR AND ITS AUXILIARIES

GENERATOR:

The 500 MW generator is a 3-phase, horizontally

mounted 2-pole cylindrical rotor type, synchronous
machine driven by steam turbine. The stator
windings are cooled by de-mineralized water
26
flowing through the hollow conductor while the rotor winding is cooled by
hydrogen gas. Fans mounted on the generator rotor facilitate the circulation of the
H2 inside the machine requiring cooling. 4 coolers mounted inside the machine
cool the H2 gas.

SPECIFICATIONS
Rated Parameters:
 Maximum Continuous MVA rating : 588 MVA
 Maximum Continuous MW rating : 500 KW
 Rated Terminal Voltage : 21 KV
 Rated Stator Current : 16200 Amps.
 Rated Power Factor : 0.85 lag

GENERATOR PROTECTION:
The core of an electrical power system is generator. During operating conditions
certain components of the generator are subjected to increase stress and therefore,
could fail, referred to as faults. It can be internal fault or external fault depending
upon whether they are inside or outside of the machine. The machine with fault
must be tripped immediately. The corrective measures against generator’s
abnormal operation are taken care by stubborn system.
Task of the protective system:
 Detect abnormal condition or defect.
 Limit its scope by switching to isolate the defect.
 Alarm the operating staff.
 Unload and/or trip the machine immediately.
Requirement of protective devices:
 Selectivity: Only that part of the installation containing fault
should is disconnected.
 Safety against faulty tripping: There should be no trip when
there is no fault.
 Reliability: The device must act within the required time.
 Sensitivity: Lowest signal input value at which the device must
act.
Primary sensing elements
Contents:
Need for measurement:
► What is measurement
 To know value of a parameter with respect to a reference.
► Need for measurement
 Safety of man & machine
 Increasing efficiency
 Better control of process parameters

Selection of instruments:
27
 ► Required accuracy of measurement
► Range of Measurement
► The form of final data display required
► Process media
► Cost
► Calibration and repair facilities required/available
► Layout restriction
► Maintenance requirement/availability

Pressure Measurement:
► Defination-pressure is defined as force per unit area
► Range –almost vacuum to very high.
► Common measuring devices
 Manometers:
► Use Water, mercury and other liquids of known density etc.
► Used For low pressure .
► Serves the Laboratory purpose for calibration use.
 Diaphragm, capsule bellows are also used.
 Bourdon tube gauges
 Different types of transducers- e.g. strain gauge Pressure at the
bottom of a fluid column of height (h) is generated by the weight of
the column of fluid divided by the area: P = F/A = W/A. Weight (W)
is a function of volume (V) and density (d). Volume V = h × A.
Therefore P = (d × h × A)/A or P = d × h. Pressure can be expressed
as head pressure in terms of the depth (h) of the fluid

28
 ► Gauge pressure is measured relative to the local ambient pressure. It's the
difference between the measured pressure and atmospheric pressure, unless
the ambient pressure surrounding the sensor is different from the
atmospheric pressure

► Vacuum is pressure measured below atmospheric pressure, referenced to

atmospheric pressure. Vacuum is negative gauge pressure.
Bourdon tube
► Operating principle-
 The process pressure causes tube to deflect. Deflection is
proportional to the pressure difference between inside and outside the
tube pressures since the outside pressure is atmospheric
► Range
 Helical bourdon - 0-0.5 Kg/cm2 up to 0-6000 kg/cm2
 ‘C’ Type bourdon - up to 700 kg/cm2
 Flat spiral bourdon - low ranges 0-70 kg/cm2

29
30
Errors in Bourdon Tube gauge measurement

Transmitters

► A transmitter has a process signal such as pressure, flow, level or

temperature as its input and an electric or pneumatic signal as its output.
► Function -Proportionally modulate an electric / pneumatic signal in
response to the process parameters.
► Electronic transmitters- These transmitters sense the change in process
variable within a certain range and produce an output current within a
range.
► Standard range- 4 to 20mA
► DP transmitters transmit the difference between pressure applied to its two
input.
Transmitter connection

Level measurement
31
 ► Level-the height of a liquid or solid above a reference line.
► Various media
 Open vessels
► DM storage Tank
► Fuel Oil Lube Oil tanks
 Closed vessels
► HP-LP heaters
► Dearator
► Condenser hot well
 Solid materials
► Coal bunker level
► Hopper level

Methods

► Basic principles
 Floats and liquid displacers
 Head pressure measurement
► Electrical / electronic
► Advanced principles
 Capacitance
 Conductance
 Radar
 Ultrasonic

Floats & Liquid displacers

Floats can be made of a hollow metal, a plastic material or molded rubber.

Floats can be used for
1.Continuous level measurement
2.Float operated switches
3.Liquid displacer systems

32
Flow measurement

► Flow is rate of crossing of a fluid at a cross sectional area.

► Measurement methods
 Differential pressure flow meters
 Variable area flow meters
 Displacement and interferential flow meters
 Electromagnetic flow meters
 Ultrasonic flow meters

Other flow measuring techniques

► Turbine Flow meter
 If a fluid moves through a pipe and acts on the vanes of a turbine, the
turbine will start to spin and rotate. The rate of spin is measured to
calculate the flow.

► Ultrasonic Doppler flow meter

 The frequency of the reflected signal is modified by the velocity and
direction of the fluid flow.
 If a fluid is moving towards a transducer, the frequency of the
returning signal will increase. As fluid moves away from a
transducer, the frequency of the returning signal decreases.
 The frequency difference is equal to the reflected frequency minus
the originating frequency and can be use to calculate the fluid flow
speed

Application in plant
► Level measurement
 Drum level-hydra step
 Bunker level-strain gauge
 CFT,MOT level-ultrasonic
► Pressure measurement
 Drum pressure-PT
 HFO pressure-PT

33
TEMPERATURE MEASURING INSTRUMENTS

WHY TEMPERATURE?

 ASSESS THE MATERIAL FATIGUE,HEAT BALANCE,HEAT

TRANSFER etc.
 ASSESSING THE PROCESS CONDITION
 EFFICIENT AND ECONOMIC OPERATION AT DETERMINED
LOAD.
 VITAL INFORMATION DISPLAY FOR SAFE OPERATION OF THE
PLANT.
 ANALYSIS

SELECTION OF INSTRUMENT:

 PRIMARY INSTRUMENTS
Thermocouple
Resistance thermometer (Pt100,Cu53)

 SECONDARY INSTRUMENTS : Uses electronic bridges (for alarm &

protection)

SELECTION OF INSTRUMENT ALSO DEPENDS ON:

 The accuracy required
 The range of temperature
 Process media on sensing element
 The layout conditions and restrictions
 Facilities available for calibration of the instrument

34
Basic idea : (exp

INTE
INCR
OBS
SUB
ITS
Basic idea : (Ex
PRINCIPLE:
LIQUIDS/GASES EXPANDS
PROPOTIONAL TO THE # ELERIS
e.g. Spiral,helical,bimetallic
CHAS
# CHA
35
 Basic idea : (Ex

# THE
THERMOCOUPLE
 THEY MUST PHYSICALLY WITHSTAND TEMPERATURE FOR
WHICH THEY ARE SELECTED
# THE
 COMPOSITION/CHARACTERISTICS SHOULD NOT CHANGE FOR SYS
THESE TEMPERATURE RANGE
# THE
 THEY SHOULD POSSESS REASONABLY LINEAR TEMPERATURE
EMF RELATIONSHIP
 THEY SHUOLD DEVELOP AN EMF PER DEG CHANGE OF
TEMPERATURE. PRE
COMBINATIONS
 IRON-CONSTANTAN, TYPE-J, RANGE: 0-760 DEG C
Constantan Cu 56-57 % Ni 43-44 %, bright and non magnetic

 CHROMEL- ALUMEL , TYPE-K, RANGE: 0-1260 DEG C

Chromel:Ni 89 %,Cr 9.8%,Fe 1%,Cobalt 0.2%,Dull & Nonmagnetic
Alumel :Ni 94.5%,Al 2%,S 1.0% Mn 2.5%,Glossy & slightly magnetic

 COPPER CONSTANTAN , TYPE-T, RANGE: -180 TO +370 DEG C

PRINCIPLE :
 CHROMEL COPEL, TYPE-E, RANGE: 0-870 DEG C

BASED ON GAS LAW PV = RT

 PLATINUM-RHODIUM-PLATINU: TYPE-S, RANGE: 0-1480 DEG C

Compensation:
PRESSURE OF THE GAS IS P
THE TEMPERATURE 36
 Resistance
Thermometer

Comp
PROPERTIES :
 Stable

temperature-resistance relationship
 Change in resistance w.r.t. temp. should be large
 Change in resistance due to strain or non temp method should beREFERENCE
less.
 Commercially available
They are Nickel, Copper and platinum
JUNCTION

THERMOCOUPLE Cons 6
1000C

JUNCTION

Stainless Steel Shealth

SIMPLIFI
PHYSICAL PROPERTIES

37
Ni : Non linear characteristic
Specific resistance 6.38 micro ohm-cm
Tempeature coefficient .0066 ohm

Cu : Linear characteristic
Specific resistance of Cu is very less(1.56 micro ohm-cm)
Temperature coefficient 53 ohm

Pt : Costly
More suitable than Cu,Ni
Specific Resistance 9.38 micro ohm-cm
Temperature coefficient 0.00385 ohm

COMPENSATION FOR LEAD WIRE RESISTANCE

RTD Vs THERMOCOUPLE

THERMOCOUPLE RTD

Require ref junction No ref junction

With constant temp. Absolute measurement

Sensitivity is less Greater sensitivity (the change in temp/deg C

is larger, micro change is measured more
easily)

No semiconductor Semiconductor material having resistance

values -100 to +450 deg C made of metal
oxides and their mix.

AUTOMATIC CONTROL
Automatic control is used in the power plants to ensure safe and efficient
operation of the plant. The type of the control system varies from the Simple
38
Pneumatic control systems on auxilliary plants to Microprocessor based control
systems on main plant loops.

BASIC AUTOMATIC CONTROL TERMS

1.PROCESS : The act of physically or chemically changing, including

combining, matter or of converting energy.
2.PLANT : Installation in which process is carried out.
3.CONTROLLED CONDITION : The physical quantity or condition of the
controlled body, process or machine which is the purpose of the system to control.
4.CONTROL SYSTEM : An arrangement of the elements interconnected and
interacting in such a way so as to maintain or to effect in a prescribed
manner,some condition of a body or process or machine which forms part of the
system.
5.DESIRED VALUE : The value of the controlled condition which the operator
wishes to maintain.
6.MEASURED VALUE : The actual value of the controlled condition.
7.DEVIATION : The difference between the measured value and the desired
value.
8.AUTOMATIC CONTROLLER : The item in a control system which compares
the desired and the measured value and operates in such a way so as to reduce the
deviation.
9.MEASURING UNIT : A unit which gives the signal corresponding to the
controlled condition.
10.CORRECTING UNIT : A unit which receives signal from the controller to
change the controlled condition.
11.OPEN LOOP CONTROL SYSTEM : A control system without the monitoring
feedback.
12.CLOSED LOOP CONTROL SYSTEM : A control system with monitoring
feedback,the deviation signal formed as a result of this feedback being used to
control the action of the correcting element in such a way so as to tend to reduce
the deviation of zero.

CLOSED LOOP CONTROL SYSTEM

The most common type of a control system used in a plant is a closed loop control
system. The controlled condition of the plant (pressure, level, flow, temperature)
is measured by the measuring unit and sends a signal to the controller of the
measured value(M.V.) .the controller receives a second signal which is the desired
signal(D.V.) for the controlled condition. The controller compares the measured
and the (Power cylinder, Control valve) to move it in such a direction so as to
reduce the deviation.
The amount the correcting unit moves and in what direction it travels depends on
the magnitude and the direction of the deviation.

M.V – D.V. = DEVIATION – (LARGE OR SMALL MAGNITUDE)

(POSITIVE OR NEGATIVE DIRECTION)

39
For example, let us consider that a closed loop control system is used to control
the temperature of air in a building. the indoor temperature is measured and
compared with the desired value of temperature and any deviation will cause
more or less fuel OIL to be burnt. The controller will see the result of its action
and adjust the fuel flow until there is no deviation. If the temperature suddenly
falls outside the building no change in the temperature will occur inside the
building due to the wall insulation. Eventually the temperature inside the building
will fall and the indoor temperature detector will detect it. The closed loop control
system will adjust the fuel oil flow until no deviation shows.

OPEN LOOP CONTROL SYSTEM

Open loop control systems are seldom used but they are used in conjunction with
the closed loop control system to improve the quality of control.
The outside temperature is measured and compared with the desired value of
temperature, and any deviation will cause more or less fuel to be burnt. The
controller will not see the results of its actions but will supply more or less fuel
according to the magnitude and direction of the deviation. If the temp. outside the
building suddenly falls, the outdoor temperature detector will detect this
immediately and the controller will immediately increase the fuel oil flow and
thus the inside temperature increases.
In this case the corrective action can be taken as soon as the outside temperature
falls. The disadvantage is that it cannot see the results of its actions and variations
in the inside temperature will occur due to boiler efficiency or amount of
ventilation.

COMBINED CLOSED AND OPEN LOOP SYSTEM

Closed loop control system is the main loop and will control the inside
temperature without any deviation. If the outside temperature suddenly falls the
open loop system will detect the fall in temperature and increase the fuel oil input
by using both types of control system together we can use the advantages of both
the systems and improve the quality of control.

DATA ACQUISITION SYSTEM:

INTRODUCTION:
Power plant is a very specialized field and requires close and simultaneous
monitoring of various plant equipments like boiler, turbine, generator, feed pump,
etc. and associated auxiliaries to maintain the continuous availability of
the unit as well as to ensure the safe and efficient operation of these equipments.
For such monitoring purposes, a lot of plant data (analog inputs) in the form of

40
physical measurements and status of equipment (digital inputs) are needed
(around 4500).
In earlier days, a central control room was used were all these measurements were
displayed in the form of indicators, recorders and some local panels in the field
were some specific monitoring was carried out.
But these indicators had the following limitations:
1. LIMITATION OF PHYSICAL SPACE.
2. LIMITATION OF SIMULTANEITY IN MONITORING
3. LIMITATION OF HISTORICAL STORAGE
4. LACK OF FLEXIBILITY
5. UNAVAILABILITY OF PROCESSED/CALCULATED
DATA

Hence, a need was felt for computerized intelligent system presenting data from
the entire plant to facilitate easy monitoring, recoding and to enable the operator
to take quick decisions regarding the operation.

COMPUTER BASED DAS

This system has the following features:

IN THE FORM OF DISPLAYS ON THE CRTS:

(with a facility of display and hard copy printout) through simple key
strokes/dedicated keys.

1.Variety of plant data in the form of analog measurements displayed on CRTs

(display units) in the form of group reviews(organized in plant functional groups).

2.GRAPHICS:
Graphics showing the replica of entire plant and its subsystems and individual
equipments embedded with live plant data-current values of temp., pressure, and
the status of different pumps through different colour codes (e.g. red for ON and
green for OFF).

3.BARS:
Bars(both vertical and horizontal) showing like analog measurements e.g. reheater
tube metal temperatures help the operator to compare the measurements to find
the hottest spot.

4.ALARM DISPLAYS:
These displays help in annunciation of a lot of abnormal conditions not covered in
the annunciation window.
These displays help in pinpointing the individual alarm,which led to a group
alarm in the annunciation window.Further exact measurements values and rate of
change there of can be seen on the CRTS.

41
5.HISTORICAL STORAGE:
X-t plot shows plot of a physical variable like main steam pressure, generator load
with time nearing different intervals like 10 secs, 1 mts, 10 mts, 1 hour, 24 hours,
even 1 day etc. Group trend shows value of different inputs collected on different
intervals over a period of time.

6.PLANT STARTUP GUIDANCE MESSAGES (PSGM) AND OPERATOR

GUIDANCE MESSAGES (OGM):
PSGM shows the different criteria, steps to be taken before starting an equipment
in the form of flow charts with the current status of the step being completed or
not. An OGM shows the various steps to be taken by the operator in the event of a
fault.

These steps are particularly very useful in starting/shut down of the unit.

ELECTROSTATIC PRECIPITATOR (ESP)

Indian coal contains about 30% of ash. The hourly consumption of coal of a
200 MW unit is about 110 tons. With this, the hourly production of ash will be 33
tons. If such large amount of ash is discharge in atmosphere, it will create heavy
air pollution thereby resulting health hazards. Hence it is necessary to precipitate
dust and ash of the flue gases.
Precipitation of ash has another advantage too. It protects the wear and
erosion of ID fan.
To achieve the above objectives, Electrostatic Precipitator (ESP) is used.
As they are efficient in precipitating particle form submicron to large size they are
preferred to mechanical precipitation.
An ESP has series of collecting and emitting electrons in a chamber
collecting electrodes are steal plates while emitting electrodes are thin wire of
2.5mm diameter and helical form. Entire ESP is a hanging structure hence the
electrodes are hung on shock bars in an alternative manner.
There are transformer and rectifiers located at the roof of chamber. Hopper
and flushing system form the base of chamber.

AN OVERVIEW OF

SSTPS, NTPC

42
 N.T.P.C.
S.S.T.P.S
SHAKTINAGAR
SONEBHADRA (U.P.)

43
 ROTOR OF L.P. TURBINE

ROTOR OF H.P. TURBINE

44
COAL HANDLING PLANT (C.H.P.)

45