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I N D U S T R I A L T R A I N I N G R E P O R T
(SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIRMENT
OF THECOURSE OF B.TECH.)
UNDERTAKEN AT
KUNDARKHI (GONDA)
SUBMITTED BY
SOHAM DE
JALPAIGURI GOVERNMENT ENGINEERING COLLEGE
14101102058
ELECTRICAL ENGINEERING
Acknowledgement
The tree of knowledge grows best when it has sturdy rootsand the strength of
them is dependent on ourintentions .First i would like to thank BAJAJ
ENERGY LIMITED for providing me the opportunity to work with them
and help me in my study .During the journey ofknowledge we meet certain
people who play a pivotal rolein ourdevelopment and its a privilege to thank
them for the same .So iwould like to take this opportunity in expressing
gratitude towards my mentor and guide in this period ofvocational training
,Mr Shirshendhu Roy .It would have been extremely difficult to cover this
course without his able guidance and mentoring .Then i am oblidged to thank
Sharma Sir ,Mukhtar Sir and Ajay Sir who all took the pains and interest in
explaining the nicks ofthermal power plant and making sure i understood
what i was seeing and learning .Thank you for bearing with me and for really
motivating me in life .
I am ever thank fullto my parents for their support .In fact many people have
contributed to this report and i would love to express my gratitude to all of
them like Tripathi Sir, Vikrant Sir, Tiwari Sir , Gyanendra Sir and many more
to whom all iam really grateful forhelping me in every way possible .
TABLE OF CONTENT
1. Introduction
BEPL
Independent powerplant
2. Operation
OperationofPowerPlant
3. Co n trol & In st ru mentation
InstrumentationControls
4. Industrial Automation
PLCs (Programmable Logic Controllers)SCADA
Introduction
Bajaj Energy Limited
Bajaj Hindustan through its SPV, Bajaj Energy Limited has setup new coal
based power generation plants of 90 MW each in the vicinity of 5 of its existing
sugar units. The five new coal based plants under Bajaj Energy were
commissioned early 2012 at Barkhera (Pilibhit), Maqsoodapur(Shahjahanpur),
Khambarkhera (Lakhimpur), Kundarkhi (Gonda), Utraula (Balrampur) in the
state of Uttar Pradesh ...
The company is solely devoted in power export to UPPCL, with all its thermal
power plants running on Indian coal arranged through CCL linkages and
domestic market.
The yearly target set for each station is defined as 85 % PLF commencing total
targeted unit generation of 648000000 KWH per year. Besides this all five
stations are performing to their best efforts to achieve their target goals set up.
With the established and developed connectivity system all five units are
connected through LAN service for easy approachable communication and
desirable day to day data sharing. All the units are well equipped by the latest
technology and designed machinery to give best efficiency and performance.
The minimum target set for station availability is 95% and every station is
acheiving it on continuous basis. With the established and developed
connectivity system all five units are connected through LAN service for easy
approachable communication and desirable day to day data sharing. All the
units are well equipped by the latest technology and designed machinery to give
best efficiency and performance.
What are independent power plants
 An independent power producer (IPP) or non-utility generator(NUG) is an
entity ,which is not a public entity,but which owns facilities to generate electric
power for sale to utilities and end users
 For the majority of IPPs, particularly in the renewable energy industry , a feed in
tariff or Power Purchase Agreement provides a long term price guarantee
 Capacity (2*45 MW)
 It is coal fired
Operation
E L E C T R I C I T Y F R O M C O A L
Coal from the coal wagons is unloaded with the help of wagon tipplers in the
C.H.P. this coal is taken to the raw coal bunkers with the help ofconveyor
belts. Coal is then transported to bowl mills by coal feeders where it is
pulverized and ground in the powered form .This crushed coal istaken away
to the furnace through coal pipes with the help ofhot and cold mixture P.A
fan. This fan takes atmospheric air, a part ofwhich is sent to pre heaters while
a part goes to the mill for temperature control. Atmospheric air from F.D fan
in the air heaters and sent to the furnace as combustion air .Water from boiler
feed pump passes through economizer and reaches the boiler drum .Water
from the drum passes through the down comers and goes to the bottom ring
header. Water from the bottom ring header is divided to all the foursides of
the furnace .Due to heat density difference the water rises up in the water wall
tubes. This steam and water mixture is again taken to the boiler drum where
the steam is sent to super heaters for super heating. The super heaters are
located inside the furnace and the steam is superheated (540 degree Celsius)
and finally itgoes to the turbine .Fuel gases from the furnace are extracted
from the induced draft fan, which maintains balance draft in the furnace with
F.D fan. These fuel gases heat energy to the various super heaters and finally
through air pre heaters and goes to electrostatic precipitators where the ash
particles are extracted. This ash is mixed with the water to from slurry is
pumped to ash period .The steam from boiler isconveyed to turbine through
the steam pipes and through stop valve and control valve that automatically
regulate the supply ofsteam to the turbine .Stop valves and controls valves are
located in steam chest and governor driven from main turbine shaft operates
the control valves the amount used.
Steam from controlled valves enter high pressure cylinder ofturbines, where it
passes through the ring of blades fixed to the cylinder wall. These act as
nozzles and direct the steam into a second ring ofmoving blades mounted on
the disc secured in the turbine shaft. The second ring turns the shaft as a result
offorce ofsteam. The stationary and moving blades work together.
Oil System
An auxiliary oil system pump is used to supply oil at the start-up of
the steam turbine generator. It supplies the hydraulic oil system
required for steam turbine's main inlet steam stop valve, the governing
control valves, the bearing and seal oil systems, the relevant hydraulic
relays and other mechanisms.
At a preset speed of the turbine during start-ups, a pump driven by the
turbine main shaft takes over the functions of the auxiliary system.
T H E R M A L P O W E R P L A N T
A Thermal Power Station comprises all ofthe equipment and a subsystem
required to produce electricity by using a steam generating boiler fired with
fossil fuels or befouls to drive an electrical generator. Some prefer to use the
term ENERGY CENTER because such facilities convert forms ofenergy, like
nuclear energy, gravitational potential energy orheat energy (derived from the
combustion offuel) into electrical energy. However ,POWER PLANT is the
most common term in the united state; While POWER STATION prevails in
many Commonwealth countries and especially in the United Kingdom. Such
power stations are most usually constructed on a very large scale and designed
forcontinuous operation. Typical diagram ofa coal fired thermal power
Typical coal thermal power station
Typical diagram of a coal-firedthermal powerstation
1. Coolingtower 10. SteamControl valve 19. Superheater
2. Coolingwaterpump 11. Highpressure steamturbine 20. Forceddraught(draft) fan
3. Transmissionline (3-phase) 12. Deaerator 21. Reheater
4. Step-uptransformer(3-phase) 13. Feedwaterheater 22. Combustion airintake
5. Electrical generator(3-phase) 14. Coal conveyor 23. Economiser
6. Low pressure steamturbine 15. Coal hopper 24. Airpreheater
7. Condensate pump 16. Coal pulverizer 25. Precipitator
8. Surface condenser 17. Boilersteamdrum 26. Induceddraught(draft) fan
9. Intermediate pressure steam
turbine
18. Bottomash hopper 27. Flue-gasstack
 Co o ling to wers
Cooling Towers are evaporative coolers used for cooling water orother
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 oilrefineries ,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 200meters tall and 100
meters in diameter, orrectangular structure that can be over 40 meter stall and
80 meters long. Smaller towers are normally factory built, while larger ones
are constructed on site. The primary use oflarge , 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 ofsome of the
cooling water in mechanical forced-draft or induced draft towers orin natural
draft hyperbolic shaped cooling towers as seen at most nuclear power plants.
Th r e e p h a s e t r a n s m i s s i o n l i n e
 Three phase electric po wer
Is a common method of electric power transmission. It is a type ofpoly phase
system mainly used to power motors and many other devices. AThree phase
system uses less conductor material to transmit electric power than equivalent
single phase, two phase, ordirect 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 ofone cycle of the electrical current. This
delay between “phases” has the effect ofgiving constant power transfer over
each cycle ofthe 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 coilor 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 aphase
separation ofone-third one cycle. Generators output at a voltage that ranges
from hundreds of volts to 30,000 volts. 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
orit 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 centre tap onone ofthe
windings supplying the ground and neutral. This allows for 240Vthree 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 and240 V between any two phase) to be available from the same
supply.
 Electrical generato r
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 orturbine steam
engine, , water falling through the turbine are made in avariety ofsizes
ranging from small 1 hp (0.75 kW) units (rare) used as mechanical drives for
pumps, compressors and other shaft driven equipment ,to2,000,000
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 ourmajor coal fired power stations to drive
thegenerators or alternators, which produce electricity. The turbines
themselves are drivenby steam generated in ‘Boilers’ or‘steam generators’ as
they are sometimes called.Electrical power station use large stem turbines
driving electric generators to producemost (about 86%)ofthe world’s
electricity. These centralized stations are oftwo types:fossil fuel power plants
and nuclear power plants. The turbines used forelectric powergeneration are
most often directly coupled to their-generators .As the generators mustrotate at
constant synchronous speeds according to the frequency ofthe electric
powersystem, the most common speeds are 3000r/min for 50 Hz systems,
and 3600 r/min for60 Hz systems. Most large nuclear sets rotate at half those
speeds, and have a 4-polegenerator rather than the more common 2-pole one
.Energy in the steam after itleaves the boiler is converted into rotational
energy as it passes through the turbine. The turbine normally consists of
several stage with each stages consisting ofa stationary blade (or nozzle) and a
rotating blade. Stationary blades convert the potential energy ofthe 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.
 Bo iler feed water pu mp
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 orretuning 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 ofthe
centrifugal pump type or positive displacement type.
 C o n s t r u c t i o n a n d o p e r a t i o n
Feed water pumps range in size up to many horsepower and the electric motor
is usually separated from the pump body by some form ofmechanical
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 isusually accomplished through the use of a centrifugal pump.
Feed water pumps usually run intermittently and are controlled by a float
switch orother 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, itssupply has been cut offor exhausted,
orits discharge is blocked); the second stage will be triggered. This stage may
switch offthe boiler equipment (preventing the boiler from running dry and
overheating), trigger an alarm, orboth.
 S t e a m - p o w e r e d p u m p s
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 ofwater 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 ofsurface 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 orboiler as boiler feed water. By condensing the exhaust
steam ofa turbine at a pressure below atmospheric pressure, the steam
pressure drop between the inlet and exhaust ofthe turbine is increased, which
increases the amount heat available forconversion to mechanical power. Most
ofthe heat liberated due to condensation of the exhaust steam is carried away
by the cooling medium (water or air) used by the surface condenser.
 Co ntro l valves
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 orclosing 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 ofcontrol valves is done by means ofelectrical, hydraulic or
pneumatic systems
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)
CONTROL AND INSTRUMENTATION
Temperature
The hotness or coldness of a piece of plastic, wood, metal, or other
material depends upon the molecular activity of the material. Kinetic
energy is a measure of the activity of the atoms which make up the
molecules of any material. Therefore, temperature is a measure of the
kinetic energy of the material in question.1.
• RTD
• The resistance of an RTD varies directly with temperature:- As
temperature increases, resistance increases.- As temperature
decreases, resistance decreases.
• RTDs are constructed using a fine, pure, metallic, spring-like wire
surrounded by an insulator and enclosed in a metal sheath.
A change in temperature will cause an RTD to heat or cool, producing
a proportional change in resistance. The change in resistance is
measured by a precision device that is calibrated to give the proper
temperature reading.2.
THERMOCOUPLES
Thermocouples will cause an electric current to flow in the attache
dcircuit when subjected to changes in temperature. The amount of
current that will be produced is dependent on the temperature
difference between the measurement and reference junction; the
characteristics of the twometals used; and the characteristics of the
attached circuit.
Heating the measuring junction of the thermocouple produces a
voltage which is greater than the voltage across the reference junction.
The difference between the two voltages is proportional to the
difference in temperature and can be measured on the voltmeter (in
mill volts). For ease of operator use, some voltmeters are set up to
read out directly in temperature through use of electronic circuitry.
Pressure Transducers Bellows-Type Detectors
The need for a pressure sensing element that was extremely sensitive
to low pressures and provided power for activating recording and
indicating mechanisms resulted in the development of the metallic
bellows pressure sensing element. The metallic bellows is most
accurate when measuring pressures from 0.5 to 75 psig. However,
when used in conjunction with a heavy range spring, some bellows
can be used to measure pressures of over 1000 psig
• Differential Flow Transmitter Orifice plates
• Flat plates 1/16 to 1/4 in. thick
• Mounted between a pair offlanges
Installed in a straight run ofsmooth pipe to avoid disturbance offlow patterns
due to fittings and valves
• Venturi tube
• Converging conical inlet, a cylindrical throat, and adiverging recovery cone
No projections into the fluid, no sharp corners, and no sudden changes in
contour
• Dall flow tube
• Consists ofa short, straight inlet section followed by an abrupt decrease in
the inside diameter ofthe tube
• Inlet shoulder followed by the converging inlet cone and a diverging exit
cone
Two cones separated by aslot orgap between the two cones
Electromagnetic flow meter
The electromagnetic flow meter issimilar in principle to the generator. The
rotorof the generator is replaced by a pipe placed between the poles ofa
magnet so that the flow of the fluid in the pipe isnormal to the magnetic field.
As the fluid flows through this magnetic field, an electromotive force is
induced in itthat will be mutually normal(perpendicular) to both the magnetic
field and the motion of the fluid. This electromotive force may be measured
with the aid ofelectrodes attached to the pipe and connected to a galvanometer
oran equivalent. For a given magnetic field, the induced voltage will be
proportional to the average velocity of the fluid. However, the fluid should
have some degree of electrical conductivity.
Power plant Controls
Drum Level Control
1. Single element water level control
Only single sensor i.e. level sensor is used to control the level
2. Double Element water level control
This uses two sensors level and flow sensors. It is better and precise than
singleelement control.
Other Temperature, Flowand Pressure control is done by
Feedback loop-
This uses a single feedback loop which finds out error from the set
point and finds out controller output
Cascaded Feedback loop control
This uses two controller:1.
Master2.
SlaveThe set point of slave controller is decided by the controller
output of the master
Feed Forward Control
Here the disturbance is eliminated even before it enters the process.
The sensor senses the disturbance and feed forward controller
nullifies the disturbance
Ratio Control
Ratio control is used to ensure that two flows are kept at the same
ratio even if the flows are changing. E.g. Air-Fuel Ratio where the
proper ratio between air and fuel i.e. pulverized coal has to be
maintained
Automation of Processes
The main purpose of automation is to minimize human
intervention to reduce the errors. Large processes like power
plant has large scope for errors. The automation of industrial
processes is carried by PLCs and SCADA
.
The above figure shows the hierarchy setup of industrial
automation. The field devices are connected to the PLC and
all the PLCs are connected to the SCADA server based in
control room. The SCADA server is connected via LAN to
ERP (Enterprise Resource Planning) and the data can be
accessed from any where on internet.
PLC (Programmable Logic Controller)
Digital electronic device that uses a programmable memory to
store instructions and to implement specific functions such as
logic ,sequencing , timing etc to control machine and
processes. Salient features• Cost effective for controlling
complex systems.• Flexible and can be reapplied to control
other systems quickly and easily.• Computational abilities
allow more sophisticated control.• Trouble shooting aids make
programming easier and reduce downtime.• Reliable
components make these likely to operate for years
beforefailure.PLC HARDWARE Many PLC configurations
are available, even from a single vendor. But, in each of these
there are common components and concepts. The most
essential components are:
Power Supply - This can be built into the PLC or be an
external unit. Common voltage levels required by the PLC
(with and without the power supply) are 24Vdc,
120Vac,220Vac.
CPU (Central Processing Unit) - This is a computer where
ladder logic is stored and processed .I/O (Input /Output) - A
number of input/output terminals must be provided so that the
PLC can monitor the process and initiate actions
Indicator lights - These indicate the status of the PLC
including power on, program running, and a fault. These are
essential when diagnosing problems. The configuration of the
PLC refers to the packaging of the components.Rack - A rack
is often large (up to 18” by 30” by 10”) and can holdmultiple
cards. When necessary, multiple racks can be connected
together. These tend to be the highest cost, but also the most
flexible and easy to maintain .INPUTS AND OUTPUTS
Inputs to, and outputs from, a PLC are necessary to monitor
and control a process. Both inputs and outputs can be
categorized into two basic types: logical or continuous.
Consider the example of a light bulb. If it can only be turned
on or off, it is logical control. If the light can be dimmed to
different levels, it is continuous. Continuous values seem
more intuitive, but logical values are preferred because they
allow more certainty, and simplify control. As a result most
controls applications (and PLCs) use logical inputs and
outputs for most applications. Hence, we will discuss logical
I/O and leave continuous I/O for later. Outputs to actuators
allow a PLC to cause something to happen in a process. A
short list of popular actuators is given below in order
of relative popularity.· Solenoid Valves - logical outputs that
can switch a hydraulic or pneumatic flow.· Lights - logical
outputs that can often be powered directly from PLCoutput
boards.· Motor Starters - motors often draw a large amount of
current when started, so they require motor starters, which are
basically large relays.· Servo Motors - a continuous output
from the PLC can command a variable speed or position
.Outputs from PLCs are often relays, but they can also be
solid state electronics such as transistors for DC outputs or
Triacs for AC outputs. Continuous outputs require special
output cards with digital to analog converters .Inputs come
from sensors that translate physical phenomena into electrical
signals. Typical examples of sensors are listed below in
relative order of popularity.· Proximity Switches - use
inductance, capacitance or light to detect an object logically.·
Switches - mechanical mechanisms will open or close
electrical contacts for a logical signal.· Potentiometer -
measures angular positions continuously, using resistance.·
LVDT (linear variable differential transformer) - measures
linear displacement
.
Drawing the ladder logic for flowchartThe flowchart is the most
encountered problems in industrial processes Ladder Logic is:
Step 1-CHECK INPUT STATUS-First the PLC takes a look at each
input to determine if it is on or off. In other words, is the sensor
connected to the first input on? How about the second input? How
about the third... It records this data into its memory to be used
during the next step .
Step 2-EXECUTE PROGRAM-Next the PLC executes your program
one instruction at a time. Maybe your program said that if the first
input was on then it should turn on the first output. Since it already
knows which inputs are on/off from the previous step it will be able to
decide whether the first output should be turned on based on the state
of the first input. It will store the execution results for use later during
the next step.
Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the
status of the outputs. It updates the outputs based on which inputs
were on during the first step and the results of executing your
program during the second step. Based on the example in step 2 it
would now turn on the first output because the first input was on and
your program said to turn on the first output when this condition is
true.
Deadman Switch
A motor will be controlled by two switches. The Go switch will start
themotor and the Stop switch will stop it. If the Stop switch was used
to stopthe motor, the Go switch must be thrown twice to start the
motor. Whenthe motor is active a light should be turned on. The Stop
switch will bewired as normally closed.
SCADA
It stands for
Supervisory Control and Data Acquisition
. It generally refers to an industrial control system: a computer system
monitoring and controlling a process .Features of SCADA1.
Supervisory Control-Generally speaking, a SCADA system usually
refers to a system that
c o o r d i n a t e s
, but does not
c o n t r o l
processes in real time. The discussion on real-time control is muddied
some what by newer telecommunications technology, enabling
reliable, low latency, high speed communications over wide areas.2.
Redundancy-When any device turns out to faulty the SCADA
software will automatically transfer the control to the
redundantsystems3.
Historical and Real Time Trends4.
Alarm-Alarms can set when a particular hi or low value is breached.5.
LAN Connectivity-It should have good LAN connectivity as it is
necessary for connecting to the ERP.6.
Dynamic Process Graphic-This has brought about revolution in
automation as previously people would not what was going in the
system VISUALLY. But with SCADA software which has large
library of symbols the whole process can be modeled accurately. And
the process can be monitored by sitting in the control room.
The software used in the SCADA was WONDERWARE INTOUCH
.The previous diagram shows the SCADA Screen of Boiler. The
important parameters are shown in model itself making it possible to
monitor the process from the control room itself
Conclusion
From all the study it can be concluded that the Kundarkhi Bajaj thermal Power plant of (2*45
MW) is a fairly organized unit with the latest machineary
The turbine is a fairly sophisticated assembly of machinery which requires specific conditions
of steam temperature and pressure to work efficiently . Any alteration to that may prove to be
hazardous.
The level of pollution is always controlled according to the established norms, which still i
consider to be quite enough .Well efforts are always underway reducing the pollution and
improving the efficiency of the plant .
All in all , a thermal power project is a very large established with many components and it
awes me to see how all the components work in a synchronized manner .

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INDUSTRIAL TRAINING REPORT.docx 1 (1)

  • 1. I N D U S T R I A L T R A I N I N G R E P O R T (SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIRMENT OF THECOURSE OF B.TECH.) UNDERTAKEN AT KUNDARKHI (GONDA) SUBMITTED BY SOHAM DE JALPAIGURI GOVERNMENT ENGINEERING COLLEGE 14101102058 ELECTRICAL ENGINEERING
  • 2. Acknowledgement The tree of knowledge grows best when it has sturdy rootsand the strength of them is dependent on ourintentions .First i would like to thank BAJAJ ENERGY LIMITED for providing me the opportunity to work with them and help me in my study .During the journey ofknowledge we meet certain people who play a pivotal rolein ourdevelopment and its a privilege to thank them for the same .So iwould like to take this opportunity in expressing gratitude towards my mentor and guide in this period ofvocational training ,Mr Shirshendhu Roy .It would have been extremely difficult to cover this course without his able guidance and mentoring .Then i am oblidged to thank Sharma Sir ,Mukhtar Sir and Ajay Sir who all took the pains and interest in explaining the nicks ofthermal power plant and making sure i understood what i was seeing and learning .Thank you for bearing with me and for really motivating me in life . I am ever thank fullto my parents for their support .In fact many people have contributed to this report and i would love to express my gratitude to all of them like Tripathi Sir, Vikrant Sir, Tiwari Sir , Gyanendra Sir and many more to whom all iam really grateful forhelping me in every way possible .
  • 3. TABLE OF CONTENT 1. Introduction BEPL Independent powerplant 2. Operation OperationofPowerPlant 3. Co n trol & In st ru mentation InstrumentationControls 4. Industrial Automation PLCs (Programmable Logic Controllers)SCADA
  • 4. Introduction Bajaj Energy Limited Bajaj Hindustan through its SPV, Bajaj Energy Limited has setup new coal based power generation plants of 90 MW each in the vicinity of 5 of its existing sugar units. The five new coal based plants under Bajaj Energy were commissioned early 2012 at Barkhera (Pilibhit), Maqsoodapur(Shahjahanpur), Khambarkhera (Lakhimpur), Kundarkhi (Gonda), Utraula (Balrampur) in the state of Uttar Pradesh ... The company is solely devoted in power export to UPPCL, with all its thermal power plants running on Indian coal arranged through CCL linkages and domestic market. The yearly target set for each station is defined as 85 % PLF commencing total targeted unit generation of 648000000 KWH per year. Besides this all five stations are performing to their best efforts to achieve their target goals set up. With the established and developed connectivity system all five units are connected through LAN service for easy approachable communication and desirable day to day data sharing. All the units are well equipped by the latest technology and designed machinery to give best efficiency and performance. The minimum target set for station availability is 95% and every station is acheiving it on continuous basis. With the established and developed connectivity system all five units are connected through LAN service for easy approachable communication and desirable day to day data sharing. All the units are well equipped by the latest technology and designed machinery to give best efficiency and performance.
  • 5. What are independent power plants  An independent power producer (IPP) or non-utility generator(NUG) is an entity ,which is not a public entity,but which owns facilities to generate electric power for sale to utilities and end users  For the majority of IPPs, particularly in the renewable energy industry , a feed in tariff or Power Purchase Agreement provides a long term price guarantee  Capacity (2*45 MW)  It is coal fired
  • 6. Operation E L E C T R I C I T Y F R O M C O A L Coal from the coal wagons is unloaded with the help of wagon tipplers in the C.H.P. this coal is taken to the raw coal bunkers with the help ofconveyor belts. Coal is then transported to bowl mills by coal feeders where it is pulverized and ground in the powered form .This crushed coal istaken away to the furnace through coal pipes with the help ofhot and cold mixture P.A fan. This fan takes atmospheric air, a part ofwhich is sent to pre heaters while a part goes to the mill for temperature control. Atmospheric air from F.D fan in the air heaters and sent to the furnace as combustion air .Water from boiler feed pump passes through economizer and reaches the boiler drum .Water from the drum passes through the down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the foursides of the furnace .Due to heat density difference the water rises up in the water wall tubes. This steam and water mixture is again taken to the boiler drum where the steam is sent to super heaters for super heating. The super heaters are located inside the furnace and the steam is superheated (540 degree Celsius) and finally itgoes to the turbine .Fuel gases from the furnace are extracted from the induced draft fan, which maintains balance draft in the furnace with F.D fan. These fuel gases heat energy to the various super heaters and finally through air pre heaters and goes to electrostatic precipitators where the ash particles are extracted. This ash is mixed with the water to from slurry is pumped to ash period .The steam from boiler isconveyed to turbine through the steam pipes and through stop valve and control valve that automatically regulate the supply ofsteam to the turbine .Stop valves and controls valves are located in steam chest and governor driven from main turbine shaft operates the control valves the amount used. Steam from controlled valves enter high pressure cylinder ofturbines, where it passes through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring ofmoving blades mounted on the disc secured in the turbine shaft. The second ring turns the shaft as a result offorce ofsteam. The stationary and moving blades work together.
  • 7. Oil System An auxiliary oil system pump is used to supply oil at the start-up of the steam turbine generator. It supplies the hydraulic oil system required for steam turbine's main inlet steam stop valve, the governing control valves, the bearing and seal oil systems, the relevant hydraulic relays and other mechanisms. At a preset speed of the turbine during start-ups, a pump driven by the turbine main shaft takes over the functions of the auxiliary system. T H E R M A L P O W E R P L A N T A Thermal Power Station comprises all ofthe equipment and a subsystem required to produce electricity by using a steam generating boiler fired with fossil fuels or befouls to drive an electrical generator. Some prefer to use the term ENERGY CENTER because such facilities convert forms ofenergy, like nuclear energy, gravitational potential energy orheat energy (derived from the
  • 8. combustion offuel) into electrical energy. However ,POWER PLANT is the most common term in the united state; While POWER STATION prevails in many Commonwealth countries and especially in the United Kingdom. Such power stations are most usually constructed on a very large scale and designed forcontinuous operation. Typical diagram ofa coal fired thermal power Typical coal thermal power station Typical diagram of a coal-firedthermal powerstation
  • 9. 1. Coolingtower 10. SteamControl valve 19. Superheater 2. Coolingwaterpump 11. Highpressure steamturbine 20. Forceddraught(draft) fan 3. Transmissionline (3-phase) 12. Deaerator 21. Reheater 4. Step-uptransformer(3-phase) 13. Feedwaterheater 22. Combustion airintake 5. Electrical generator(3-phase) 14. Coal conveyor 23. Economiser 6. Low pressure steamturbine 15. Coal hopper 24. Airpreheater 7. Condensate pump 16. Coal pulverizer 25. Precipitator 8. Surface condenser 17. Boilersteamdrum 26. Induceddraught(draft) fan 9. Intermediate pressure steam turbine 18. Bottomash hopper 27. Flue-gasstack  Co o ling to wers Cooling Towers are evaporative coolers used for cooling water orother 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 oilrefineries ,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 200meters tall and 100 meters in diameter, orrectangular structure that can be over 40 meter stall and 80 meters long. Smaller towers are normally factory built, while larger ones are constructed on site. The primary use oflarge , 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 ofsome of the cooling water in mechanical forced-draft or induced draft towers orin natural draft hyperbolic shaped cooling towers as seen at most nuclear power plants.
  • 10. Th r e e p h a s e t r a n s m i s s i o n l i n e  Three phase electric po wer Is a common method of electric power transmission. It is a type ofpoly phase system mainly used to power motors and many other devices. AThree phase system uses less conductor material to transmit electric power than equivalent single phase, two phase, ordirect 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 ofone cycle of the electrical current. This delay between “phases” has the effect ofgiving constant power transfer over each cycle ofthe 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 coilor 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 aphase separation ofone-third one cycle. Generators output at a voltage that ranges
  • 11. from hundreds of volts to 30,000 volts. 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 orit 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 centre tap onone ofthe windings supplying the ground and neutral. This allows for 240Vthree 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 and240 V between any two phase) to be available from the same supply.  Electrical generato r 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 orturbine steam engine, , water falling through the turbine are made in avariety ofsizes ranging from small 1 hp (0.75 kW) units (rare) used as mechanical drives for pumps, compressors and other shaft driven equipment ,to2,000,000 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 ourmajor coal fired power stations to drive thegenerators or alternators, which produce electricity. The turbines themselves are drivenby steam generated in ‘Boilers’ or‘steam generators’ as they are sometimes called.Electrical power station use large stem turbines driving electric generators to producemost (about 86%)ofthe world’s electricity. These centralized stations are oftwo types:fossil fuel power plants and nuclear power plants. The turbines used forelectric powergeneration are most often directly coupled to their-generators .As the generators mustrotate at constant synchronous speeds according to the frequency ofthe electric
  • 12. powersystem, the most common speeds are 3000r/min for 50 Hz systems, and 3600 r/min for60 Hz systems. Most large nuclear sets rotate at half those speeds, and have a 4-polegenerator rather than the more common 2-pole one .Energy in the steam after itleaves the boiler is converted into rotational energy as it passes through the turbine. The turbine normally consists of several stage with each stages consisting ofa stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential energy ofthe 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.  Bo iler feed water pu mp 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 orretuning 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 ofthe centrifugal pump type or positive displacement type.
  • 13.  C o n s t r u c t i o n a n d o p e r a t i o n Feed water pumps range in size up to many horsepower and the electric motor is usually separated from the pump body by some form ofmechanical 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
  • 14. sufficient pressure to overcome the steam pressure developed by the boiler. This isusually accomplished through the use of a centrifugal pump. Feed water pumps usually run intermittently and are controlled by a float switch orother 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, itssupply has been cut offor exhausted, orits discharge is blocked); the second stage will be triggered. This stage may switch offthe boiler equipment (preventing the boiler from running dry and overheating), trigger an alarm, orboth.  S t e a m - p o w e r e d p u m p s 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 ofwater 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 ofsurface 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 orboiler as boiler feed water. By condensing the exhaust steam ofa turbine at a pressure below atmospheric pressure, the steam pressure drop between the inlet and exhaust ofthe turbine is increased, which increases the amount heat available forconversion to mechanical power. Most ofthe heat liberated due to condensation of the exhaust steam is carried away by the cooling medium (water or air) used by the surface condenser.  Co ntro l valves
  • 15. 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 orclosing 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 ofcontrol valves is done by means ofelectrical, hydraulic or pneumatic systems 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)
  • 16. CONTROL AND INSTRUMENTATION Temperature The hotness or coldness of a piece of plastic, wood, metal, or other material depends upon the molecular activity of the material. Kinetic energy is a measure of the activity of the atoms which make up the molecules of any material. Therefore, temperature is a measure of the kinetic energy of the material in question.1. • RTD • The resistance of an RTD varies directly with temperature:- As temperature increases, resistance increases.- As temperature decreases, resistance decreases.
  • 17. • RTDs are constructed using a fine, pure, metallic, spring-like wire surrounded by an insulator and enclosed in a metal sheath. A change in temperature will cause an RTD to heat or cool, producing a proportional change in resistance. The change in resistance is measured by a precision device that is calibrated to give the proper temperature reading.2. THERMOCOUPLES Thermocouples will cause an electric current to flow in the attache dcircuit when subjected to changes in temperature. The amount of current that will be produced is dependent on the temperature difference between the measurement and reference junction; the characteristics of the twometals used; and the characteristics of the attached circuit.
  • 18. Heating the measuring junction of the thermocouple produces a voltage which is greater than the voltage across the reference junction. The difference between the two voltages is proportional to the difference in temperature and can be measured on the voltmeter (in mill volts). For ease of operator use, some voltmeters are set up to read out directly in temperature through use of electronic circuitry. Pressure Transducers Bellows-Type Detectors The need for a pressure sensing element that was extremely sensitive to low pressures and provided power for activating recording and indicating mechanisms resulted in the development of the metallic
  • 19. bellows pressure sensing element. The metallic bellows is most accurate when measuring pressures from 0.5 to 75 psig. However, when used in conjunction with a heavy range spring, some bellows can be used to measure pressures of over 1000 psig • Differential Flow Transmitter Orifice plates • Flat plates 1/16 to 1/4 in. thick • Mounted between a pair offlanges Installed in a straight run ofsmooth pipe to avoid disturbance offlow patterns due to fittings and valves • Venturi tube • Converging conical inlet, a cylindrical throat, and adiverging recovery cone No projections into the fluid, no sharp corners, and no sudden changes in contour • Dall flow tube • Consists ofa short, straight inlet section followed by an abrupt decrease in the inside diameter ofthe tube • Inlet shoulder followed by the converging inlet cone and a diverging exit cone
  • 20. Two cones separated by aslot orgap between the two cones Electromagnetic flow meter The electromagnetic flow meter issimilar in principle to the generator. The rotorof the generator is replaced by a pipe placed between the poles ofa magnet so that the flow of the fluid in the pipe isnormal to the magnetic field. As the fluid flows through this magnetic field, an electromotive force is induced in itthat will be mutually normal(perpendicular) to both the magnetic field and the motion of the fluid. This electromotive force may be measured with the aid ofelectrodes attached to the pipe and connected to a galvanometer oran equivalent. For a given magnetic field, the induced voltage will be proportional to the average velocity of the fluid. However, the fluid should have some degree of electrical conductivity. Power plant Controls Drum Level Control 1. Single element water level control Only single sensor i.e. level sensor is used to control the level 2. Double Element water level control This uses two sensors level and flow sensors. It is better and precise than singleelement control. Other Temperature, Flowand Pressure control is done by
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  • 22. Feedback loop- This uses a single feedback loop which finds out error from the set point and finds out controller output Cascaded Feedback loop control This uses two controller:1. Master2.
  • 23. SlaveThe set point of slave controller is decided by the controller output of the master Feed Forward Control Here the disturbance is eliminated even before it enters the process. The sensor senses the disturbance and feed forward controller nullifies the disturbance Ratio Control Ratio control is used to ensure that two flows are kept at the same ratio even if the flows are changing. E.g. Air-Fuel Ratio where the proper ratio between air and fuel i.e. pulverized coal has to be maintained Automation of Processes The main purpose of automation is to minimize human intervention to reduce the errors. Large processes like power plant has large scope for errors. The automation of industrial processes is carried by PLCs and SCADA . The above figure shows the hierarchy setup of industrial automation. The field devices are connected to the PLC and all the PLCs are connected to the SCADA server based in control room. The SCADA server is connected via LAN to ERP (Enterprise Resource Planning) and the data can be accessed from any where on internet.
  • 24. PLC (Programmable Logic Controller) Digital electronic device that uses a programmable memory to store instructions and to implement specific functions such as logic ,sequencing , timing etc to control machine and processes. Salient features• Cost effective for controlling complex systems.• Flexible and can be reapplied to control other systems quickly and easily.• Computational abilities allow more sophisticated control.• Trouble shooting aids make programming easier and reduce downtime.• Reliable components make these likely to operate for years beforefailure.PLC HARDWARE Many PLC configurations
  • 25. are available, even from a single vendor. But, in each of these there are common components and concepts. The most essential components are: Power Supply - This can be built into the PLC or be an external unit. Common voltage levels required by the PLC (with and without the power supply) are 24Vdc, 120Vac,220Vac. CPU (Central Processing Unit) - This is a computer where ladder logic is stored and processed .I/O (Input /Output) - A number of input/output terminals must be provided so that the PLC can monitor the process and initiate actions Indicator lights - These indicate the status of the PLC including power on, program running, and a fault. These are essential when diagnosing problems. The configuration of the PLC refers to the packaging of the components.Rack - A rack is often large (up to 18” by 30” by 10”) and can holdmultiple cards. When necessary, multiple racks can be connected together. These tend to be the highest cost, but also the most flexible and easy to maintain .INPUTS AND OUTPUTS Inputs to, and outputs from, a PLC are necessary to monitor and control a process. Both inputs and outputs can be categorized into two basic types: logical or continuous. Consider the example of a light bulb. If it can only be turned on or off, it is logical control. If the light can be dimmed to different levels, it is continuous. Continuous values seem more intuitive, but logical values are preferred because they allow more certainty, and simplify control. As a result most controls applications (and PLCs) use logical inputs and outputs for most applications. Hence, we will discuss logical I/O and leave continuous I/O for later. Outputs to actuators
  • 26. allow a PLC to cause something to happen in a process. A short list of popular actuators is given below in order of relative popularity.· Solenoid Valves - logical outputs that can switch a hydraulic or pneumatic flow.· Lights - logical outputs that can often be powered directly from PLCoutput boards.· Motor Starters - motors often draw a large amount of current when started, so they require motor starters, which are basically large relays.· Servo Motors - a continuous output from the PLC can command a variable speed or position .Outputs from PLCs are often relays, but they can also be solid state electronics such as transistors for DC outputs or Triacs for AC outputs. Continuous outputs require special output cards with digital to analog converters .Inputs come from sensors that translate physical phenomena into electrical signals. Typical examples of sensors are listed below in relative order of popularity.· Proximity Switches - use inductance, capacitance or light to detect an object logically.· Switches - mechanical mechanisms will open or close electrical contacts for a logical signal.· Potentiometer - measures angular positions continuously, using resistance.· LVDT (linear variable differential transformer) - measures linear displacement .
  • 27. Drawing the ladder logic for flowchartThe flowchart is the most encountered problems in industrial processes Ladder Logic is: Step 1-CHECK INPUT STATUS-First the PLC takes a look at each input to determine if it is on or off. In other words, is the sensor connected to the first input on? How about the second input? How about the third... It records this data into its memory to be used during the next step . Step 2-EXECUTE PROGRAM-Next the PLC executes your program one instruction at a time. Maybe your program said that if the first input was on then it should turn on the first output. Since it already knows which inputs are on/off from the previous step it will be able to decide whether the first output should be turned on based on the state
  • 28. of the first input. It will store the execution results for use later during the next step. Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the status of the outputs. It updates the outputs based on which inputs were on during the first step and the results of executing your program during the second step. Based on the example in step 2 it would now turn on the first output because the first input was on and your program said to turn on the first output when this condition is true.
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  • 31. Deadman Switch A motor will be controlled by two switches. The Go switch will start themotor and the Stop switch will stop it. If the Stop switch was used to stopthe motor, the Go switch must be thrown twice to start the motor. Whenthe motor is active a light should be turned on. The Stop switch will bewired as normally closed.
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  • 34. SCADA It stands for Supervisory Control and Data Acquisition . It generally refers to an industrial control system: a computer system monitoring and controlling a process .Features of SCADA1. Supervisory Control-Generally speaking, a SCADA system usually refers to a system that c o o r d i n a t e s , but does not c o n t r o l processes in real time. The discussion on real-time control is muddied some what by newer telecommunications technology, enabling reliable, low latency, high speed communications over wide areas.2. Redundancy-When any device turns out to faulty the SCADA software will automatically transfer the control to the redundantsystems3. Historical and Real Time Trends4. Alarm-Alarms can set when a particular hi or low value is breached.5. LAN Connectivity-It should have good LAN connectivity as it is necessary for connecting to the ERP.6. Dynamic Process Graphic-This has brought about revolution in automation as previously people would not what was going in the system VISUALLY. But with SCADA software which has large library of symbols the whole process can be modeled accurately. And the process can be monitored by sitting in the control room. The software used in the SCADA was WONDERWARE INTOUCH .The previous diagram shows the SCADA Screen of Boiler. The
  • 35. important parameters are shown in model itself making it possible to monitor the process from the control room itself
  • 36. Conclusion From all the study it can be concluded that the Kundarkhi Bajaj thermal Power plant of (2*45 MW) is a fairly organized unit with the latest machineary The turbine is a fairly sophisticated assembly of machinery which requires specific conditions of steam temperature and pressure to work efficiently . Any alteration to that may prove to be hazardous. The level of pollution is always controlled according to the established norms, which still i consider to be quite enough .Well efforts are always underway reducing the pollution and improving the efficiency of the plant . All in all , a thermal power project is a very large established with many components and it awes me to see how all the components work in a synchronized manner .