Thermal Power Plant In-Plant Training

1. 1

2. IN-PLANT TRAINING
IN
U.P.R.V.U.N.L
A.T.P. ANPARA
SONEBHADRA
(U.P.)
Submitted by: - In
guidance of:-
Shrayam Srivastava (1007001) Er. A.K. Pandey (E.E.)
HINDUSTAN UNIV. (CHENNAI) Er. S.K. Sagar (A.E.)
B.E. (E.I.E) - 2ND
Year
FROM:-22/12/11 TO 20/01/12
2

3. Acknowledgement
I have gone through the in-plant training of 4 weeks in ANPARA
THERMAL POWER STATION, ANPARA, SONEBHADRA (U.P.).
During this period I learned many things basically regarding my
subject. Above this I learned many operational and control of
some more fields too. I faced many practical problems and
found their solutions.
I am very grateful to ELECTRONICS AND INSTRUMENTATION
DEPARTMENT OF HINDUSTAN UNIV., CHENNAI (T.N.) for
granting me permission and a golden chance to take my
practical learning to higher level. I would like to thank Mrs.
Manjula Pramod (HOD, EIE) for giving me such a chance and Mr.
G. Muthukumaran for guiding me in further process.
I am also thankful to whole staff of A.T.P.P. who helped as well
as encouraged me through my work specially staff of B.T.P.S. I
am thankful to Mr. A.K. Pandey (Executive Engineer) and Mr. S.K.
Sagar (Assistant Engineer) and all staff members of this
department including J.E.s, Technicians, and others for
providing me an opportunity to have practical exposure on
Control and Instrumentation Division- 1 (C&I MD-1) in Anpara (B)
Thermal Power Project, Anpara of U.P.R.V.U.N.L.. I pay my
sincere gratitude to Er. Suneel Kumar Gangawar, A.E C&I MD-II
for his valuable contribution and important guidance. I also pay
my sincere gratitude to Er. Rafyuddin, J.E C&I MD-I for his
valuable contribution and important guidance in control lab and
plant.
I want to give regards to those who helped directly or indirectly,
specially my parents. I want to thank my dad Mr. Sanjay
Srivastava CHEM –II (O&G CHD) and my mom Mrs. Renu
srivastava for helping me in throughout process and being
reason of my focus.
3

4. Shrayam Srivastava
certificAte
It is to certify that Shrayam Srivastava of II-year B.E.
(E.I.E) Of HINDUSTAN UNIV. CHENNAI (T.N.) has
done training from 22/12/11 to 20/01/12 in C&I (MD-I)
(2×500MW) BTPS, ANPARA, SONEBHADRA (U.P.).
The report was made under my supervision, and I
express my delight on it successful completion. I am also
very happy to offer my guidance whenever it is required.
During training period he was very sincere and his
behavior and conduct was excellent.
I want his success in all future endeavors.
(Er. A.K. PANDEY)
EXECUTIVE ENGINEER
C&I MD-I, BTPS
4

5. (Er. S.K. SAGAR)
ASSISTANT ENGINEER
C&I MD-1, BTPS
AnPArA ‘B’
tHermAl Power
StAtion
in
control
And
inStrUmentAtion
diViSion (c&i md-1)
5

6. indeX
1. PREFACE.
2. INTRODUCTION.
3. PICTORIAL DESCRIPTION.
4. UNIT OVERVIEW, DETAILS,
DESCRIPTION.
5. UNIT ELECTRICAL OVERVIEW.
6. CIRCULATING WATER SYSTEM.
7. WATER SYSTEM.
8. AIR FLOW SYSYTEM.
9. STEAM FLOW SYSTEM.
6

7. 10. IMPORATAN PARTS DETAILED.
11. ROLE OF CONTROL &
INSTRUMENTATION IN POWER PLANT.
12. BIBLIOGRAPHY.
P r e f A c e
SO WHAT EXACTLY IS ELECTRICITY?
E L E C T R I C I T Y B Y D E F I N I T I O N I S E L E C T R I C
C U R R E N T T H A T I S U S E D A S A P O W E R
S O U R C E . T H I S E L E C T R I C C U R R E N T I S
G E N E R A T E D I N A P O W E R P L A N T , A N D T H E N
S E N T O U T O V E R A P O W E R G R I D T O Y O U R
H O M E S , A N D U L T I M A T E L Y T O Y O U R P O W E R
O U T L E T S .
7

8. introdUction
U.P.R.V.U.N.L. IS UTTAR PRADESH RAJYA VIDHUT UTPADAN
NIGAM LIMITED. It is a state government organization
producing 1630MW. The site of Anpara Thermal Power
Station is situated at the border of Uttar Pradesh and
Chhatisgarh, at the southernmost tip of Distt. Sonebhadra
(U.P.) and on the left bank of Rihand reservoir along the
national highway near town Anpara and 3km from existing
Renusagar Thermal Power Station .
Thermal power:
The heat released by the combustion of coal produces steam
in a boiler at high pressure and temperature which when
through steam turbine gives mechanical power. The steam
turbine acts as a prime mover and drives the synchronous
generator.
In India at present about 61% of power generated are
thermal and the rest 32% come from hydro station and rest
7% is from other sources like wind energy plants, nuclear
8

9. plants etc. . Coal is used as fuel in most of steam plants; the
rest depends on oil and natural gas and fossil fuel.
Anpara Thermal Power Project is divided into two sub
plants:
• ATPS (3X210 MW).
• BTPS (2X500 MW).
The electrical machinery and equipments used in ATPS are
almost of Bharat Heavy Electrical Limited (BHEL) in
collaboration with Germany and Russia while BTPS has
been established by Mitsui Co., Tokyo, Japan.
Electrical Power Generated in ATPS is at 15.75KV while in
BTPS is at 21KV. The power in both units is stepped up to a
voltage level of 400KV for transmission through 400KV bus
bar for economic consideration. A fraction of generated
power is also stepped down to 6.9KV to feed the station
requirements.
SYNCHRONISATIONS
UNIT FIRST SYNCHRONISATION COMERCIAL
LOAD
Unit-1 24-03-1986 01-01-1987
Unit-2 28-02-1987 01-06-1987
9

10. Unit-3 12-08-1988 01-04-1989
Unit-4 19-07-1993 01-03-1994
Unit-5 04-07-1994 01-10-1994
introdUction to AnPArA
Power Project
TOTAL PROPOSED CAPACITY: 4130MW IN 3 STAGES
(3×210MW + 2×500MW +
3×500MW+2×500MW)
PRESENT CAPACITY : ATPS - 3×210MW
BTPS - 2×500MW
DTPS - 2×500MW
PROJECT COST : ATPS - Rs. 721 CRORES
BTPS - Rs. 2060
CRORES
10

11. MAJOR REQUIRMENTS:
COAL : Source - Kakri, Bina &
Khadia coal
Mines
Maximum Consumption : 49940m3
/Day
F grade coal
WATER : Source – Rihand
reservoir
Cooling Water Req. : 75cu. m.
Chimney stack height : ATPS-225 meters.
BTPS-275 meters.
Ash Disposal : 10% Ash slurry pumped
to ash dyke.
11

12. Commencement of work : July 1980.
PictoriAl
deScriPtion
1.
12
POWER
UNIT
CIRCULATING
WATER SYSTEM
WATER SYSTEM
AIRFLOW
SYSTEM
STEAM FLOW
SYSTEM
BOILER FEED
PUMP

13. 2.
CIRCULATING WATER SYSTEMCIRCULATING WATER SYSTEM
CIRCULATING WATER SYSTEM-1CIRCULATING WATER SYSTEM-1
CIRCULATING WATER SYSTEM-2CIRCULATING WATER SYSTEM-2
CIRCULATING WATER PUMPCIRCULATING WATER PUMP
13

14. 3.
WATER SYSTEMWATER SYSTEM
CONDENSATECONDENSATE
SRW &HDPSRW &HDP
FEEDWATERFEEDWATER
CEP (A-C)CEP (A-C)
BOILER DRUMBOILER DRUM
LP HEATERLP HEATER
HP HEATERHP HEATER
ACWP (A-D)ACWP (A-D)
14

15. 4.
AIR FLOW SYSTEMAIR FLOW SYSTEM
PRIMARY AIR PATHPRIMARY AIR PATH
SECONDARY AIR PATHSECONDARY AIR PATH
FLUE GAS PATHFLUE GAS PATH
STEAM FLOW SYSTEMSTEAM FLOW SYSTEM
STEAM FLOWSTEAM FLOW
AUX STEAMAUX STEAM
15

16. 5.
Unit overview
BOILER FEED PUMPBOILER FEED PUMP
BFP- T(A) STEAMBFP- T(A) STEAM
BFP-T(A) LUB. OILBFP-T(A) LUB. OIL
BFP-T(B) STEAMBFP-T(B) STEAM
BFP-T(B) LUB. OILBFP-T(B) LUB. OIL
M-BFPM-BFP
BFP Brg Vib. &temp.BFP Brg Vib. &temp.
16

17. Pictorial diagram:
17

18. Unit detailS:
Anpara B Power Station Unit.-4:
• B-Power Station constitutes of two units each capable for
500 MW output.
• Boiler efficiency : 88.93%.
• Turbine efficiency: 42.93%.
• Unit Heat Rate: 2216.7KC/KWH.
• Generator output factor: 500 MW at 50Hz (lagging)
power.
Unit SPeciFication:
STEAM TURBINE UNIT-5:
• Type: TCDF.
• Rated output: 500 MW.
• Rated Speed: 3000 RPM.
STEAM CONDITIONS:
• Initial Pressure: 169 Kg/cm2
.
• Initial Temperature: 5380 Celsius
.
• Reheat Temperature: 5380 Celsius
.
• Exhaust Pressure: 76.6 mm Hg (ABS).
• First Synchronization: 04-07-1994.
18

19. AC GENERATOR UNIT-5:
• Made: Toshiba Corp., Tokyo, Japan.
• Phase: 3.
• Type: TAKS.
• Form: LCH.
• Poles: 2.
• KVA: 589000.
• RPM: 3000.
• Volts: 21000.
• Amperes: 16194.
• Hertz: 50.
• Rating: Continuous.
• Power Factor: 0.8 (Lag.).
• Inlet Coolant Temperature: 480
Celsius.
• Rated Field Volts: 392.
• Field Amps. : 4810.
• Stator Connection: Star.
• Permissible Over Speed: 3600 RPM.
• Stator & Rotor Insulation Class: F
19

20. MBFP:
• Type Form: DV-CH.
• FW QUANTITY: 545T/Hr.
• Total Head: 6.5 kg/cm2
(stage-1).
• Suction Pressure: 10 kg/cm2
.
• Discharge Pressure: 16.5 kg/cm2
g.
• RPM: 1485.
• FW TEMP. : 1740
celcius.
HYDRAULIC COUPLING:
• Type: GSS 47-CS45.
• Rating: 4900 KW.
• Input Speed: 1485 RPM.
• Output Speed: 5660 RPM.
• Type Of Gear: Single Helical.
• Gear Ratio: 3.89.
BFP:
• Type Form: BGM-GH.
• F.W. Flow: 545 T/Hr.
• Total Head: 208.5kg/cm2
(stage-6).
• Suction Pressure: 15.5kg/cm2
g.
• Discharge Pressure: 224 kg/cm2
g.
20

21. Unit deScriPtion
In a diagram there is a boiler, which is half filled
with water and half filled with steam. This saturated
steam (containing some amount of water) is passed
through super heater to remove its water content.
Water is necessary to be removed because it can
produce corrosion in the blades of turbine. Now the
temp of this steam is 540 degree centigrade and
pressure turbine. Steam expands and pressure is
169 kg/cm sq. this super heated (SH) steam is
subjected to high pressure (HP) turbine. Steam
expands on the blades of turbine and its pressure
and temperature decreases. This steam is again
passed through re-heater (RH) to increase its temp
up to 540 deg. Centi. again, so that maximum
utilization can be made. This re-heated steam is
subjected to intermediate pressure (IP) turbine
where it expands up to very low pressure. After this
its not possible to reheat the steam coz pressure is
very low so we flow it LP turbine This pressure is
further decreases in low pressure turbine to obtain
maximum work done. This steam is kept in vaccum
actually it’s not vaccum its pressure less than atm.
Pressure, so it doesn’t get converted into water or
wet steam before reaching the condenser. The
steam reaches to condenser where cooling water is
used to cool the steam. This make-up water is
obtained from cooling water treatment plant (DM
Plant). De-mineralized water is mixed with make up
water in hot well. The rate of mixing is
61.7tonnes/Hr.
The shaft of the turbine is connected with generator
and mechanical energy is converted into electrical
energy using Faraday’s law. The voltage obtained
21

22. at the output of generator is 21KV having frequency
of 50Hz.
Condensed water is passed through condensed
extracted pump (CEP) and then through condensed
polishing plant (CPP) to acquire necessary pH
value and maintain some other qualities of water.
It is necessary to maintain the pH of water because
acidic water can torn out the pipe and basic water
can deposit layers on the walls of boiler that
reduces stability and increases the heat
requirements of boiler. Normal pH of water is used
for plant purpose is 8.Pressure of this water is 26
kg/cm sq. and its pH value is -3.15. This water is
taken to low pressure super heater (LPSH) at the
rate of 1395tonnes/Hr.
From LPSH water goes to De-aerator. De-aerator is
used to remove the oxygen from condensed water
because oxygen is harmful for proper operation of
boiler. It may form rust.
De-aerator has a deflector, which is used to
separate steam from water. Its structure is spiral
due to which when saturated steam proceeds
through this, water being heavier comes, in the
central part and drops down due to gravity.
If some amount of oxygen remains even after de-
aerator, then hydrazine is used to remove this extra
oxygen.
The reaction is:
N2H4 + O2  N2 + 2H2O
22

23. Nitrogen is an inert gas. So it doesn’t make any
harmful effect on boiler walls.
Condensed water after passing through De-aerator
becomes feed water and this feed water is raised
up to a pressure of 195kg/cm sq. from nearly
30kg/cm sq. this is done using boiler feed pump.
This unit has 4 boilers feed pumps (BFP) among
which 2 are in operation at a time. 2 BFPs are
motor driven and 2 BFPs are turbine driven. Initially
motors drive BFPs and after synchronization other
2 BFPs are driven by turbine.
Since feed water has very high pressure of
195kg/cm sq. So it is heated in high pressure super
heater (HPSH) at a rate of 1515tonnes/Hr. this
water is then taken to economizer.
Economizer is a part of the furnace used to
increase efficiency by further increasing the temp.
of feed water. From here water is fed to boiler
drum. To raise the temp. of water heating is done
and coal is used as a fuel for burning. This fuel
comes from mills. This unit has 8 mills i.e. mill (A-
H).
Each mill has one bunker. Thus there are 8 bunkers
in each unit. Capacity of each bunker is 2000 tones.
All the 8 bunkers store 16000 tones of coal and
extra coal is deposited in a yard with the help of
stack-reclaimed.
23

24. This is a machine, which is used to either stack or
reclaim coal. There is a all time water spraying
system provided in the yard to wet the coal and
protect it from gradual burning.
Coal from the bunkers is taken to ball mills where it
is crushed into fine particles.
Ball mills contain several balls, which continuously
rotate and strike with each other and with coal
pieces with the help of a cylinder.
These fine particles are taken to furnace by primary
air. Primary air acts as a carrier. This air has a
great pressure and it is heated in air pre heater
(APH).
APH is a rotating device and it has various
sections. From one side air comes in these sections
and from other side flue gas comes in. the section
in contact of flue gas observes heat from it and
after rotation comes in contact of air to raise its
temp.
One more component of air called as secondary air
is also taken to furnace for combustion purpose.
For this process forced draught (FD) fans are used.
From burning of coal flue gas is produced. This flue
gas consist s of a large amount of ash. To remove
the ash electrostatic precipitator (ESP) is used. Ash
free flue gas is sucked through induced draught
fans (ID) and reaches to chimney from where it is
thrown to atmosphere.4 ESP’s are used for each
unit. 2 are working at a time. Other 2 are redundant.
ESP has 2 plates: cathode and anode so that ash
particles stick to them and due to regular
24

25. hammering, they down after sometime. Some
content of this ash is mixed with water and this wet
ash is taken out from plant through thick pipes.
Remaining dry ash is removed from plant by trucks
or aim is to minimize pollution and maximize
efficiency.
For this it is necessary to use the heat energy of
flue gas in the plant itself. This heat energy is used
in economizer and air pre heater (APH). 2 pre
heaters are used for primary air known as primary
pre heater and 2 are used for secondary air known
as secondary air pre heater. After absorbing its
heat, temperature comes down to about 150 0
c.
Now it can be extracted through chimney.
In this plant there are 3 chimneys. One chimney’s
height is 275 m, which is largest is Asia.
Unit electrical
overview
25

26. Unit electrical overview shows how the generated power is
amplified and transferred to transformers through 2-phase
& 3-phase power supply system.
26

27. Generator system:
As the turbine moves the generator is also moves and
magnetic lines of force are cut by the coil and hence
electricity is produced in the coil. We have to supply
excited magnetic field first. Generally in small generators
they have their own exciter and any other exciter will not
be attached but in large generators, exciter unit is
compulsory.
Small generators are cooled by air, but bigger auxiliary
are cooled by hydgen. In big generators the stator coil is
also cooled by water. When turbine moves in its rated
speed the generator’s rotor also moves at that speed to
give moving flux generated in the stator which produces
the electricity.
Transformer system:
To increase or decrease voltage we use step down
transformer. There are two types of Transformer used in
the thermal project.
• Main Transformer
• Auxiliary Transformer
The main transformer takes the generated voltage as
21KV from generator, after then it converts to 440KV as
required. There are many other small systems related to
these systems. Which are responsible for managing and
controlling these systems and also to increase the
efficiency of the thermal project. These processes are by
pass steam reaching to the turbine to increase the
efficiency.
27

28. circUlating water
SyStem
28

29. 29

30. 30

31. Description:
Circulating water pump house is situated in the east of
main power house building at 1Km. distance. Water comes
from Rihand dam through open canal. There is common
structure for ATPS and BTPS called intake structure. Four
Nos. of traveling water screen are working to screen the
water of DAM, and then the water comes to common pit of
C.W. Pumps of almost equal capacity (15640m3
/Hr) of
A&BTPS. 13 no. of C.W. pumps fulfils the requirement of
2X500MW of BTPS Anpara.
Discharge water of 7 nos. of C.W. pumps of BTPS goes to
condenser of unit 4 through a duct then return through
outlet duct and open channel to DAM. Discharge water of
another 6 nos. of C.W. and one common pump 4 G of unit
4&5 goes to condenser of unit 5 through another duct and
open channel to DAM.
Thus there are 3 nos. of underground parallel duct from
C.W. pump house to main power house. One goes to
ATPS as three common units, one to unit 4 and one to unit
5. There are 13 air releasing vent in each duct from which
air automatically releases.
General description:
C.W. Pumps of BTPS.
MAKE : BHEL, HYDERABAD
CAPACITY : 15640m3
/Hr
HEAD : 36.5m
RATED SPEED : 493 RPM
QUANTITY : 10 + 1x2(STAND BY)
+ 1(COMMON)
STAND BY
31

32. WATER SYSTEM
Condenser:
Steam after rotating steam turbine comes to condenser. Condenser
refers here to the shell and tube heat exchanger (or surface
condenser) installed at the outlet of every steam turbine in Thermal
power stations of utility companies generally. These condensers are
heat exchangers which convert steam from its gaseous to its liquid
state, also known as phase transition. In so doing, the latent heat of
steam is given out inside the condenser. Where water is in short
supply an air cooled condenser is often used. An air cooled
condenser is however significantly more expensive and cannot
achieve as low a steam turbine backpressure (and therefore less
32

33. efficient) as a surface condenser. The purpose is to condense the
outlet (or exhaust) steam from steam turbine to obtain maximum
efficiency and also to get the condensed steam in the form of pure
water, otherwise known as condensate, back to steam generator or
(boiler) as boiler feed water.
Boiler:
Now that pulverized coal is put in boiler furnace. Boiler is an
enclosed vessel in which water is heated and circulated until the
water is turned in to steam at the required pressure.
Coal is burned inside the combustion chamber of boiler. The
products of combustion are nothing but gases. These gases
which are at high temperature vaporize the water inside the
boiler to steam. Some times this steam is further heated in a
33

34. super heater as higher the steam pressure and temperature the
greater efficiency the engine will have in converting the heat in
steam in to mechanical work. This steam at high pressure and
temperature is used directly as a heating medium, or as the
working fluid in a prime mover to convert thermal energy to
mechanical work, which in turn may be converted to electrical
energy. Although other fluids are sometimes used for these
purposes, water is by far the most common because of its
economy and suitable thermodynamic characteristics.
34

35. HPHS:
• High Pressure Heaters are used to heat the
deaerated water at higher temperature 2500
C.
• Heat is obtained from extended turbine steam.
35

36. LPHS:
• Low Pressure Heaters are used to pre-heat the
supply at the rate of 1191.4T/HR.
• Typically three separate heaters are present per
unit.
• Heat is obtained from one of the extended steam
supplied from turbine.
• Output is given to Deaerator.
AiR floW SYSTEM
36

37. Description:
37

38. Before furnace:
The forced draft fans are horizontal single stage
double suction centrifugal type each directly
coupled with a driving motor by means of a gear
coupling. The fan delivered air flow is controlled by
adjusting the opening of inlet vanes. Each fan is
composed of the casing, rotor shaft, impeller wheel,
bearings and inlet vanes.
These force draft (F.D.) fans provides positive draft
as it gives air pressure and oxygen supply to air
heater and further to boiler. This positive draft is not
only given by F.D. fans there are two primary air
fans (P.A.). They force this atmospheric oxygen to
furnace of boiler for conversion of water to steam.
This air is passed through primary air heaters to
make it easy for combustion. This part is known as
primary and secondary air path.
In furnace:
The whole combustion process is done there; the
conversion of water to steam is done there.
After furnace:
At the economizers the negative draft is generated
by I.D. fan. These induced draft fans are horizontal
single stage double suction centrifugal type and
coupled with a driving motor through a hydraulic
coupling. The fan delivery gas flow is controlled by
adjusting the fan speed and inlet vanes. Each fan is
composed mainly of the casing, rotor shaft, impeller
wheel, bearings and inlet vanes. In meanwhile
there are 4 electrostatic precipitators (ESPs) in unit
4 and 4 in unit 5.These precipitators utilize the
electrostatic forces to separate dust particles from
the flue gas to be cleaned. The gas is conducted to
a chamber containing “curtains” of vertical steel
plates. These curtains divide the chamber into a no.
38

39. of gas passages. A frame with secured wires is
located within each to form a rigid framework.
STEAM SYSTEM
39

40. PRODUCTION OF STEAM:
Coal is unloaded from transport services to
track hopper of Coal Handling Plant. This coal
is transported up to the raw Coal Bunkers with
the help of Belt Conveyor. Coal is taken to Ball
Mill by coal feeders. The coal is ‘pulverized’ in
the ball mills by coal feeders. This
pulverization is done through rollers and
rotating table. This coal is taken to furnace
through pipes by warming it up using PA Fans.
Thus this coal combustion produces heat and
feed water from boiler feed pump (BFPs)
passes through high pressure heaters (HP)
and low pressure heaters (LP), economizers
too. This process produces steam.
40

41. iMpoRTAnT pARTS
dETAilEd:
DEAERATOR:
• It removes the Oxygen and other dissolved
gasses i.e. CO2 etc from the feed water to
steam generating boilers.
• It is situated at a height above the LPHS.
• Its output is given to boiler feed pumps.
M-BFP/T-BFP:
• These are the basic feed pump units that feed
the water to HPHS.
• M-BFP are used at starting time, they are
motor driven.
• T-BFP are used at running time, they are
steam driven.
TURBINE:
• SH (Super Heated) steam at 5410
C and
166.4Kg/cm2
is fed to HP Turbine and
circulated back to furnace. Super heater: Most
of the modern boilers are having super heater
and reheated arrangement. Super heater is a
component of a steam-generating unit in
which steam, after it has left the boiler drum,
is heated above its saturation temperature.
The amount of superheat added to the steam
is influenced by the location, arrangement,
41

42. and amount of super heater surface installed,
as well as the rating of the boiler. The super
heater may consist of one or more stages of
tube banks arranged to effectively transfer
heat from the products of combustion. Super
heaters are classified as convection, radiant
or combination of these.
• RH (Re Heated) steam at 5390
C and 36
Kg/cm2
is fed to IP (Intermediate Pressure)
turbine and then directly to low pressure (LP)
Turbine. Reheater: Some of the heat of
superheated steam is used to rotate the
turbine where it loses some of its energy.
Reheater is also steam boiler component in
which heat is added to this intermediate-
pressure steam, which has given up some of
its energy in expansion through the high-
pressure turbine. The steam after reheating is
used to rotate the second steam turbine (see
Layout fig) where the heat is converted to
mechanical energy. This mechanical energy is
used to run the alternator, which is coupled to
turbine, there by generating electrical energy.
• All three are connected through common shaft
to Alternator.
• Turbine shaft rotates at 3000rpm.
FUEL SYSTEM:
42

43. According to this diagram the oil consumption is
shown.
43

44. Role of
electRonics
instRumentation
and contRol in
poweR plant
44

45. instRumentation
In modern process industry or Thermal Power
Stations - Control and Instrumentation plays vital
role for its proper operation and quality generation
of output products. The instrumentation is the most
important part of control and instrumentation field. It
is divided mainly in following subgroups for the
measurement of different types of parameters in big
Thermal Power Station as 2X500 MW, BTP,
ANPARA:-
•Parametric Measurement (Temperature
Measurement).
•Manometer Measurement (Pressure, DP, Flow,
Level, etc.).
• Analytical Measurement (Conductivity, PH,
O2, CO2, Si, H2, etc.).
In our 2X500MW ,BTP, ANPARA all the above
measurements are done with the help of
sophisticated transducers (primary instruments) and
the signals are processed and finally indicated and
recorded on modern secondary instrument through
“Data Acquisition System” etc., each of the above
measurement field is very wide and modern. We
45

46. shall discuss them on the basis of these
measurements being used in our 2X500MW, BTP,
ANPARA.
pYRometRic
measuRement
RESISTANCE TEMPERATURE DETECTORS
(RTD’S):
RTD’S are high precision devices used to measure
temperature in corrosive and no corrosive media.
They work on the principle of variation of resistance
of a sensing element, usually made of Platinum,
with corresponding changes in temperature.
Basically there are three types of sensors:
• Thin Film
• Wire Wound Ceramic
• Wire Wound Glass
These sensors are encapsulated in a metal sheath
made of Stainless Steel or any other suitable metal.
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47. The leads of the sensors are silver brazed to the
wires which run through multimode ceramic tubes
which are terminated in porcelain terminal box 1st
the head of assembly.
GENERAL SPECIFIC ATIONS:
ELEMENT: DIN Pt 50, Pt 100, Pt 130, Pt 200,
Pt 1000
JIS Pt 50, Pt 100
GOST and BS
INSULATION: Multibore ceramic beads on
compact magnesium oxide
THERMOCOUPLES:
Thermocouples are devices based on the principal
known as See beck effect. A current flows in a
closed circuit made out of two dissimilar metals, if
the junctions are kept at different temperature.
This results in an electromotive force (emf) being
generated which is proportional to temperature
difference.
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48. A Thermocouple consists of a metal sheath in which
the thermoelectric elements are embedded in highly
compacted magnesium oxide insulation or
multimode ceramic beads.
These elements are terminated in a porcelain
terminal block which is enclosed in an explosion
proof.
The hot junction of the element wires can be of
three types:
• Grounded for fast response.
• Ungrounded for isolation.
• Exposed for the immediate response.
TEMPERATURE GUAGES/SWITCHES
In general we are using “mercury in steel tube”
thermometer type temperature gauges/switches for
the local measurement of all 6.6kV to 0.4KV
auxiliary bearing, winding, cooling water inlet/outlet
temperature measurement, etc.
PYROMETERS
Photoelectric optical pyrometers or radiation type
pyrometers are used the non-contact type
temperature measurement.
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49. We have optical pyrometers for furnace
temperature measurement.
It is a manual instrument. By controlling filament
temperature and matching it with furnace gives
indirectly the furnace temperature on pyrometer’s
dials.
THERMOWELLS
Thermo wells strictly as per costumer’s specification
and drawings , thermo wells are generally used as a
protective shield for the probe or other sheath of an
RTD or Thermocouple or temperature gauge.
These are made from bar stock of stainless steel,
carbon steel, alloys etc. as per requirement and the
operating temperature, special Thermo wells in
ceramics, ptfe, satellite, haste alloy, nickel, titanium,
tantalum, silver etc. are made for trouble free
operation in the most hostile operating conditions.”
TEMPERATURE TRANSMITTERS
Temperature transmitter are used to convert low
level sensor signals from RTD’s and thermocouple
to high level 4-20mA or 1-5V dc signals which can
be transmitted to distant instruments.
RTD’S:
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50. THERMOCOUPLES:
TEMPERATURE TRANSMITTERS:
manometRic
measuRements
In 2X500, ATP, Anpara, we are using following
type/s of manometric measurements.
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51. • Absolute/Relative pressure measurements
• Differential pressure measurements
• Level measurements
• Flow measurements
• Pressure gauges/switches etc.
All the above manometric measurements from
S.No.1 to 4 have quite similarity in their general
structure & operating principles. A general operating
principle of a transmitter is described below:
PRINCIPLE OF OPERATION:
All the pressure, differential pressure, level, flow
transmitter operates on “FORCE BALANCE
PRINCIPLE” stated as “Pressure applied to the
bellow unit results in a force being applied to the
transmission bars.’ This force is proportional to the
pressure applied to the bellow units.”
The transmission bars attached at its lower end the
bellow units has its fulcrum at the fulcrum
diaphragm seal & is connected at its opposite end
to the vector linkage at point ‘A’. The vector is
attached to the unit via the span adjustment
mechanism at point ‘C’. This force applied at point
‘A’ will produce a further related force at point ‘C’. In
the following figure the appropriate arrow shows the
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52. direction of each force. The relationship between
the force ‘A’ and force ‘B’ is determined by the
tangent of α.
INDUSTRIAL TYPE PRESSURE GAUGES:
Pressure gauges are being used to measure the
pressure or vacuum. The types of pressure gauges
are designer for the industries such as chemicals,
refineries, engineering etc.These gauges are not
recommended for the use of certain corrosive slurry
and viscous media.
In order to maintain high degree of accuracy,
sufficient over-range protection is provided to
bourdon tubes. These instruments in Aluminum
casing is generally weather proof. In SS casing this
can be made proof as per the requirement of the
user.
BELLOWS:
Bellows are thin walled cylindrical shells with deep
convolution and are sensed to other end. The
sealed end moves axially when pressure is applied
in the other end. The number of convolution
varies from 5 to 20 depending on the pressure
range, displacement required and operating
temperature.
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53. GRaVitational
tRanduceRs
MANOMETER:
Manometer may be described as a liquid balance
similar in operation to mechanical laboratory
balance an unknown pressure is applied to the
manometer. This pressure forces the manometer
liquid up in the tube, increasing the height of the
column liquid and at the same time , increasing it’s
weight .when the weight of the column equals the
force exerted by the applied pressure, the
manometer is balanced and the column stabilizes.
The height of the column multiply by its density is
equal to pressure at bottom of column. His pressure
is equal to the pressure being measured. There are
different types of manometer used, some of them
are as follows:-
• Tube manometer
• Well type manometer
• Inclined manometer
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54. MEASUREMENT OF TEMPERATURE:
Temperature is the most important variable in
industrial processing, primarily because it is a
fundamental condition characteristic of a Thermal
state of a body in industrial processes this thermal
certain chemical processes are whether desirable
chemical reaction takes place as in manufactured is
correct.
Temperature measurement can be made in many
ways. The most common and most important
methods are listed below –
1. Liquid in glass thermometer
2. Programmable temperature
3. Gas thermometer
4. Thermocouples
5. Radiation and optical parameters
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55. BiBlioGRaphY
The sources that helped me are:
1. POWER PLANT LIBRARY.
2. DOCUMENTATIONS FROM ENGINEERS.
3. INTERNET.
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56. THANK YOU
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