INDUSTRIAL TRAINING

REPORT

CONTROL AND
INSTRUMENTATION
NTPC , SHAKTINAGAR
 ACKNOWLEDGEMENT

I convey my gratitude and sincere acknowledgement to Mr

NIRMAL SHARMA (AGM, C&I DEPARTMENT) for his
kind permission, enabling me to undergo training at C&I LAB.

I express my deep sense of gratitude to Mr S.KACHHWAHA

(Manager) and Mr A.K.AHMED (Assistant Engineer) for his
guidance and kind help extended to me in order to successfully
complete my training by providing with adequate information &
all required inputs.

I would like to thank them for providing me technical

knowledge and
arranging introductory sessions for innovative and in depth
understanding of the working procedures.
 CONTENTS

TOPICS
•ABOUT NTPC

• ABOUT NTPC SHAKTINAGAR

• TECHNICAL
SPECIFICATION
OF NTPC SHAKTINAGAR

•WORKING OF A PLANT

•TECHNICAL TERMINOLOGY

•MAJOR C&I SYSTEMS i.e. SG & TG packages

•FUNCTIONS OF C&I DEPARTMENT

•ABOUT MAXDNA SYSTEMS USA

•CONCLUSION
 ABOUT NTPC

POWER GENERATION
Presently, NTPC generates power from Coal and Gas.
With an installed capacity of 31,704 MW, NTPC is the
largest power generating major in the country. It has also
diversified into hydro power, coal mining, power
equipment manufacturing, oil & gas exploration, power
trading & distribution. With an increasing presence in
the power value chain, NTPC is well on its way to
becoming an “Integrated Power Major.” NTPC has been
recently accorded ”MAHARATAN” Status by
honourable GOVERNMENT OF INDIA.
While leading the nation’s power generation league,
NTPC has remained committed to the environment. It
continues to take various pro-active measures for
protection of the environment and ecology around its
projects.
NTPC was the first among power utilities in India to start
Environment Impact Assessment (EIA) studies and
reinforced it with Periodic Environmental Audits.
NTPC is the largest thermal power generating company
of India .A Public sector Company wholly owned by
government of India. It was incorporated in the year
1975 to accelerate power development in the country.
Within a span of 30 years, NTPC has emerged as a truly
national power company, with power generating
facilities in all the major regions of the country.
Contributing 26% of the country’s entire power
generation. NTPC today lights up every fourth bulb in
the country.With ambitious growth plans to become a
56000MW power company by 2017, NTPC the largest
power utility of India has already diversified into hydro
sector. 18 NTPC stations have already been accredited
with the ISO 14001 certification. In keeping with its well
focused environment protection policy, NTPC has set up
a “Centre for Power Efficiency and Environmental
protection” (CENPEEP) which functions as a resource
centre for development and dissemination of latest
technologies in environmental management. At present,
Government of India holds 89.5% of the total equity
shares of the company and the balance 10.5% is held by
FIIs, Domestic Banks, Public and others. Within a span
of 32 years, NTPC has emerged as a truly national power
company, with power generating facilities in all the
major regions of the country.
 Coal Stations
Commissioned Capacity
S.No Coal based State
(MW)
1. Singrauli Uttar Pradesh 2,000
2. Korba Chattisgarh 2,100
3. Ramagundam Andhra Pradesh 2,600
4. Farakka West Bengal 1,600
5. Vindhyachal Madhya Pradesh 3,260@
6. Rihand Uttar Pradesh 2,000
7. Kahalgaon Bihar 840@
8. Dadri Uttar Pradesh 840
9. Talcher Kaniha Orissa 3,000
10. Unchahar Uttar Pradesh 840@
11. Talcher Thermal Orissa 460
12. Simhadri Andhra Pradesh 1,000
13. Tanda Uttar Pradesh 440

Total (Coal) 20,480

@Capacity presently under implementation

Vindhyachal 1000 MW
Unchahar 210 MW

Gas/Liquid Fuel Stations

Commissioned Capacity
s.no Gas based State
(MW)
14. Anta Rajasthan 413
15. Auraiya Uttar Pradesh 652
16. Kawas Gujarat 645
17. Dadri Uttar Pradesh 817
18. Jhanor-Gandhar Gujarat 648
19. Kayamkulam Kerala 350
20. Faridabad Haryana 430
Total (Gas) 3,955
Through Joint Venture 314
 Grand Total (Coal + Gas + JV) 23,749

ABOUT
NTPC SHAKTINAGAR
Shaktinagar Super Thermal Power station is one of the
most prestigious flagships of NTPC striving ahead to
bridge the country generation gap especially in the
western region. NTPC is the sixth largest thermal power
generator in the world and the second most efficient
utility in terms of capacity utilization based on data of
1998.
The station is located in Singrauli district in MP in the
north-western side of the country. It has secured ISO
14001 and ISO 9002 certificate in the field of
environment and power generation but also in various
other fields. On November 2009, it made glorious
achievement by ensuring production up to 3260 MW. By
next few months, it adds 1000 MW more to its capacity
(i.e. 4260 MW)
As a public sector company, it was incorporated in the
year 1975 to accelerate power development in the
country as a wholly owned company of the Government
of India. At present, Government of India holds 89.5% of
the total equity shares of the company and the balance
10.5% is held by FIIs, Domestic Banks, public and
others. Within a span of 31 years, NTPC has emerged as
a truly national power company, with power generating
facilities in all the major regions of the country.
NTPC Vindhyachal super thermal power project is one
of the most prestigious flagships of NTPC striving ahead
to bridge the country generation gap especially in the
western region.
The station is located in Sidhi district in MP in the
northwestern side of the country. It has secured ISO
14001 and ISO 9002 certificate in the field of
environment and power generation but also in various
other fields. On September 2002 it made glorious
achievement by ensuring production up to 2260 MW. By
next 06 months it adds 1000MW more to its capacity
(3260MW). Work for Stage-III is going on in full swing.
The erection work has been completed before scheduled.
 TECHNICAL SPECIFICATION
ABOUT NTPC VINDHYACHAL

TYPE OF STATION - THERMAL

STATION CAPACITY - STAGE I 6 x 210

STAGE II 2 X
500
STAGE III 2 X
500
STAGE IV 2 X
500 (UNDER CONSTRUCTION)

FUEL - COAL

COAL SOURCE - NIGHAI (NCL)

TRANSPORTATION - BY RAIL

COOLING WATER SOURCE - RIHAND

RESERVIOR

ASH DISPOSAL - RIHAND

RESERVIOR

CHIMNEY –
FOR 210 MW PLANT –
210m
FOR 500 MW PLANT –
265m
PLANT AREA - 90-200 ACRES

SOURCES FOR RAW MATERIALS

COAL SOURCE
Northern coalfields limited (NCL) mines at Dudhichua
(7Km) and Nigahi (10Km) and Jayant (5Km).

FUEL OIL SOURCE

Indian oil corporation (IOC) COLD (customer operated
lubricant and oil deposit) at Jayant.

WATER SOURCE
Discharge canal of Singrauli super thermal power
station.

BENEFICIARY STATES

Madhya Pradesh, Chattisgarh, Maharastra, Gujarat,

Daman & Diu and Dadar & Nagerhaveli.
 BASIC POWER PLANT CYCLE
The thermal (steam) power plant uses a dual (vapor +
liquid) phase cycle. It is a closed cycle to enable the
working fluid (water) to be used again and again. The
cycle used is “Ranking Cycle” modified to include
super heating of steam, regenerative feed water heating
and reheating of steam Figure 1A shows this cycle and
is self explanatory.
 WORKING OF A THERMAL
POWER PLANT

COAL TO STEAM

Coal from the coal wagons is unloaded in the coal

handling plant. This Coal is transported up to the raw
coal bunkers (1) with the help of belt conveyors. Coal is
transported to Bowl Mills (3) by Coal feeders (2) the
coal is pulverized in the Bowl Mill, where it is ground
to a powder form. The mill consists of a round metallic
table on which coal particles fall. This table is rotated
with the help of a motor. There are three large steel
rollers which are spaced 120 apart. When there is no
coal, these rollers does not rotate but when the coal is
fed to the table it packs up between roller and the table
and this forces the rollers to rotate. Coal is crushed by
the crushing action between the rollers and rotating
table. This crushed coal is taken away to the furnace
through coal pipes (4) with the help of hot and cold air
mixture from P.A. Fan (5). P.A. Fan taken atmospheric
air, a part of which is sent to Air preheaters (7) for
heating while a part goes directly to the mill for
temperature control. Atmospheric air from F.D. Fan
(18) is heated in the air heaters (7) and sent to the
furnace (6) as combustion air. .
Water from the boiler feed pump passes through
economizer (8) and reaches the boiler drum (9). Water
from the drum passes through down comers and goes to
bottom ring header. Water from the bottom ring header
is divided to all the four sides of the Furnace. Due to
heat and the density difference the water rises up in the
water wall tubes (12). Water is partly converted to
steam as it rises up in the furnace. This steam and water
mixture is again taken to the boiler drum (9) where the
steam is separated from water. Water follows the same
path while the steam is sent to super heaters for
superheating. The super heaters are located inside the
furnace and the steam is superheated (540°C) and
finally it goes to turbine. Flue gases from the furnace is
extracted by induced draft fan (14) which maintains
balance draft in the furnace (-5 to -10mm of wcl) with
forced draft fan (18). These flue gases emits their heat
energy to various super heaters in the pant house (15)
and finally passes through air preheaters (7)and goes to
electrostatic precipitator (16) where the ash particles are
extracted. Electrostatic precipitator consists of metal
plates which are electrically charged. Ash particles are
attracted on to these plates, so that they do not pass
through the chimney (17) to pollute the atmosphere.
Regular mechanical hammers blows cause the
accumulation of ash to fall to the bottom of the
precipitator where they are collected in a hopper for
disposal. This ash is mixed with water to form slurry
and is pumped to ash pond.
STEAM TO MECHANICAL POWER
As can be seen from figure 2, from the boiler, a steam
pipe (1) conveys steam to the turbine through a stop
valve (which can be used to shut off steam in an
emergency) and through control valves (2) that
automatically regulate the supply of steam to the turbine.
Stop valve and control valves are located in a steam
chest and a governor (3), driven from the main turbine
shaft (4), operates the control valves to regulate the
amount of steam used (This depends upon the speed of
the turbine and the amount of electricity required from
the generator).

Steam from the control valves enters the high pressure

cylinder of the turbine, where it passes through a ring of
stationary blades (5) fixed to the cylinder wall (6). These
act as nozzles and direct the steam into a second. Ring of
moving blades (7) mounted. On a disc secured to the
turbine shaft. This second ring turns the shafts as a result
of the force of the steam. The stationary and moving
blades together constitute a ‘stage’ of the turbine and in
practice many stages are necessary, so that the cylinder
contains a number of rings of stationary blades with
rings of moving blades arranged between them. The
steam passes through each stage in turn until it reaches
the end of the high pressure cylinder and in its passage
some of its heat energy is changed into mechanical
energy.

The steam leaving the high pressure cylinder goes back

to the boiler for reheating (8) and returns by a further
pipe (9) to the intermediate pressure cylinder. Here it
passes through another series of stationary and moving
blades.

Finally, the steam is taken to the low pressure cylinders,

each of which it enters at the centre (10) flowing
outwards in opposite directions through the rows of
turbine blades - an arrangement known as double flow -
to the extremities of the cylinder. As the steam gives up
its heat energy to drive the turbine, its temperature and
pressure fall and it expands. Because of this expansion
the blades are much larger and longer towards the low
pressure ends of the turbine.

The turbine shaft usually rotates at 3,000 revolutions per

minute. This speed is determined by the frequency of the
electrical system used in this country and is the speed at
which a 2- pole generator must be driven to generate
alternating current at a frequency of 50 cycles per
second.

When as much energy as possible has been extracted

from the steam it is exhausted directly to the condenser.
This runs the length of the low pressure part of the
turbine and may be beneath or on either side of it. The
condenser consists of a large vessel containing some
20,000 tubes, each about 25mm in diameter. Cold water
from the river, estuary, sea or cooling tower is circulated
through these tubes and as the steam from the turbine
passes round them it is rapidly condensed into water
condensate. Because water has a much smaller
comparative volume than steam, a vacuum is created in
the condenser. This allows the steam to reduce down to
pressure below that of the normal atmosphere and more
energy can be utilized.

From the condenser, the condensate is pumped through

low pressure heaters by the extraction pump, after which
its pressure is raised to boiler pressure by the boiler feed
pump. It is passed through further feed heater to the
economizer and the boiler for reconversion into steam.

Where the cooling water for power stations is drawn

from large rivers, estuaries or the coast, it can be
returned directly to the source after use. Power status
situated on smaller rivers and inland do not have such
vast water resources available, so the cooling water is
passed through cooling towers (where its heat is removed
by evaporation) and re-used.

A power station generating 2,000,000 kilowatts (KW) of

electricity requires about 2,27,500 cubic meters pf water
an hour for cooling purposes. Where cooling towers are
used, about one hundredth part of the cooling water
evaporates and a certain amount is returned to its source
to carry away any impurities that collect. Most of it
however is recirculated.
.
The thermal power plant generates electricity using
steam which is generated inside boiler by burning coal or
oil.
Firstly, the coal is sent to the bunkers of a RC (Raw
Coal) feeder from which it is sent to pulverisers at a
controlled rate. The pulveriser has a grinder and three
rollers at a distance of 2.5mm rotating in opposite
directions. The powdered coal (of size less than or equal
to 2.5mm) is sent to furnace through pipes. The coal is
fed in through pipes in four directions so as to maintain
the temp. inside boiler homogeneous. The coal is sent to
furnace with the help of PA fans (Primary Air Fans).
The igniter ignites the coal which is coming inside the
furnace in such a way so that the direction of air through
PA fan is tangent to an imaginary circle. This helps in
making hot air in shape of a turbulent like structure
which saves the furnace from damage due to uneven
heating on any part of furnace.
Another fan called FD fan (Forced Draft Fan) is used for
secondary air i.e. excess air required for combustion. The
furnace walls have water pipes which absorb the heat of
combustion and changes water to water vapour. The
furnace has a goose shaped structure which saves the
platen super heater pipes from melting due to direct heat
produced from combustion of coal. The steam from
down comer goes to drum which consists of a turbo
separator. The steam and water gets separated out and
the water is
sent to water walls through risers. The drum has an
important role as it saves the turbine from water which
causes corrosion and thus passes only dry steam.
The dry steam is then passed through LTSH (Low
Temperature Super Heater) and then to platen super
heater for gaining excess heat. This steam is sent to HPT
(High Pressure Turbine) where it has a temp. of 540
degree Celsius and a pressure of 140-145 kg/cm2.
After doing work (rotating turbine) it has a temp. of 350
degree Celsius and a pressure of 40 kg/c m2 . This
steam, CRH (Cold Reheat) is passed through reheater
and then to final superheater and is called HRH (Hot
Reheat). The steam now has a temp. of 540 degree
Celsius and a pressure of 38 kg/c m2 and passed through
IPT (Intermediate Pressure Turbine).
Then the steam is passed through LPT (Low Pressure
Turbine) with 7.5-8 kg/cm2 and 350- 370 degree Celsius
of temp. All the three turbines have a common shaft
which is connected to generator from which electricity is
produced. The steam is passed through cooled water in
tubes where a pressure of 0.9 atm. is being maintained so
that the steam flows in a single direction.
The cooled steam is collected in a large container called
hot well decause the water droplets collected is still hot.
This hot water is extracted through CEP (Condensate
Extraction Pump) to drain cooler where it has a temp. of
40 degree Celsius and a pressure of 22 kg/c m2 . This is
passed through LP1 ,LP2 ,LP3 (Low Pressure heaters)
with 50, 55 and 60 degree Celsius of temp. respectively.
Now, it is passed from deareator where dissolved
harmful gases such as sulphur dioxides are removed and
then passed to feed water storage tank. The BFP’s
(Boiler Feed Pump) are used to send this to HPH (High
Pressure Heaters) at a pressure of 190-195 kg/cm2. The
BFP consists of two parts namely booster pump and
main pump. The HPH output is connected to
economisers and then to drum. The above cycle repeats
for generation of electricity.
Figure demonstrating the general outlook of a thermal Power station.
 TECHNICAL TERMINOLOGY
RC FEEDER

The function is to decide amount of coal (i.e. powdered

coal) to be given in the furnace for heating.
Considering the case if the amount of coal given to
furnace is more than required then as a result due to
more heating more steam will be produced. Then due to
more steam
more pressure will be generated.
Here we use two types of valves:-
1) Electromotive relief valve
2) Mechanical safety valve
Here when the pressure in the furnace is more than the
set point then the valve get
opened and the steam is released in the atmosphere until
the pressure drops to the set point and then the valve gets
closed.
But steam loss is more in mechanical safety valve thus,
electromotive relief valve is introduced.
BOILER LOAD INDEX

It is the index in which load of boiler is indicated.

Load of boiler means the amount of coal which is being
burnt in the furnace.

FEEDER

The crushed raw coal is delivered from the bunkers to

the individual, which in these feed the coal at a
controlled rate to the pulverisers. In order to avoid
overloading the pulverisation motor due to overfeeding
and interrupting circuits should be used to reduce coal
feed. If the motor become overloaded we start the coal
feed again to make motor load normal.

PROCESS DELAY

Suddenly when there is pressure drop, then to raise the

steam pressure to set point we have to give more amount
of coal (to produce more steam). Now it takes time to
raise the steam pressure after giving the coal to furnace
(as it takes some time to produce steam). This time is
taken is the delay generated known as process delay.
So process delay is the delay so as to have the steam
pressure being raised to set point when we have to add
coal in furnace due to pressure drop.

PRESSURE VARIATION

When there is a sudden pressure drop we can obviously

say that there is pressure variation in the steam pressure
from the set point (i.e. desired pressure).

LOAD CUTOFF

When the load of the boiler is more than the desired then
this situation is dangerous.
Now to overcome this condition we use load cut-off
which stops the connection of load and boiler i.e. cut-off
of load is done for prevention.
There 2 types of pressure in consideration:-
1) Throttle pressure
2) Limit pressure
GRID BALANCING (Reduction of grid balancing)

1) RGMO – Restricted governing mode of control

2) FGMO – Free governing mode of control
Nowadays, RGMO is mostly used instead of FGMO.
Now we consider the case when steam is given to the
turbine, then steam does work and as a result turbine
waves and thus rotor moves. The rotor waves at constant
speed. Now initially steam does work mechanically and
thus rotor moves. As a result magnetic field is generated.
Due to thismagnetic field a current is generated and thus
electricity is produced.
As the process starts from initial state we observe that it
rises slowly and reaches to the set or desired point value.

LARGE VIDEO SCREEN (LVS)

It is the screen on which various parameters used in the

process are displayed with their value.
ENGINEERING WORK STATION(EWS)

It is used by engineers to change/alter the limit or range

of any instrument

TYPES OF FAN :

1) Forced Draft (FD) Fan: Its function is to enable easy

combustion of grounded coal in furnace. It sucks from
the atmospheric air which gets heated in the air heaters
and then sent to the boiler .It also supplies hot air to PA
Fan if required as per the atmospheric conditions.

2) Induced Draft (ID) Fan: The air heater receives heat

from the boiler and hence the air accompanied there
contains a huge amount of ash. This air is then passed
through ESP and finally exhausted through the chimney
with the help of ID fans.

3) Primary Air (PA) Fan: Its function is to blow the

crushes coal from ball mill to furnace through pipes. It
operates using three type of air:- hot air, cold air and
atmospheric air.
ELECTROSTATIC PRECIPITATOR

Here fly ash is separated from flue gas and then through
ash hammering ash is collected and then passed through
a system which is of two types:-

1) Wet system: - The dry ash is mixed with water to form

slurry and then with ash slurry pump this slurry is sent to
ash deck.

2) Dry fly ash system: - In this system no water is mixed

with ash and the obtained Dry ash is given to cement /
brick industries.
MAJOR C&I SYSTEMS
INCLUDED UNDER MAIN PLANT
i.e. SG & TG
The SG & TG C&I systems are based on state of the art
of the microprocessor technology with CRT/KBD
operation facilities. Operation through back up
conventional
control devices is also possible. These C&I systems are
procured under the respective main plant package i.e.
SG/TG package.

THE SG-C&I SYSTEM

The SG-C&I system includes the following
microprocessor based systems:-
1. Furnace safeguard supervisory system for purging,
automatic firing, flame monitoring, sequential start-up
and shut down of mills etc.
2. Secondary air damper control system
3. Auxiliary PDRS control system
4. Soot boiler control system
5. Coal feeder controls
6. Control of electromagnetic safety valve
7. Furnace temp. Probes Each of these functional blocks
is provided as independent systems which are connected
through redundant system bus to achieve integrated
CRT/KBD operation & monitoring.

THE TG-C&I SYSTEM

The TG-C&I system includes the following functional

blocks:-
1. EHG control system
2. Automatic Turbine Run Up System (ATRS)
3. HP-LP bypass control system
4. Turbine Stress Control System (TSCS)
5. Automatic Turbine Testing System (ATT)
6. Turbine protection system
7. Turbine Supervisory Instruments (TSI) Except for
TSI, all other functional blocks are connected through
redundant system bus to achieve integrated CRT/KBD
operation & monitoring.
 FUNCTIONS OF C&I
DEPARTMENT
Control and instrumentation in any process industry, can
be compared to the nerve system in the human being.
The way the nerve system controls the operation of
various limbs of human beings, C&I in the same way
controls and operates various motors, pumps, etc and
thus helps us to achieve our targets.
C&I, as the name indicates, is a branch in engineering
which deals with various measurement, indication,
transmission and control in different technical field. The
term instrument means “A device or combination of
devices used directly or indirectly to measure and display
a variable.” Instrumentation is a measurement of various
parameters with comparison to set standards. In
industries and process plants, Instrumentation makes use
of various measuring components designed to suit the
process and the purpose. As some of the big industries
and process plant need to control different process
variable from a remote distance control room, the further
measuring, transmitting, indicating, recording and
innovative.
The main work of C&I department is to observe, control
and manipulate electrical as well as non-electrical
quantities like temperature, pressure, vibrations etc. So
first these signals are converted into digital signals by “A
to D ” convertors. These are combinations of
microprocessors and microcontrollers which contain
certain logic coding and algorithm which convert analog
signals to digital signals. C&I department governs the
whole functioning and operation of power plant through
the Central Control System (DDC-MIS) “Distributed
Digital Control Monitoring and Information System”.
ABOUT MAXDNA SYSTEMS USA
The maxDNA Plant Automation System (PAS) is the
latest version of Distributed control system developed by
Metso Automation MAX Controls, US. MaxDNA works
with the popular operating systems Microsoft Windows
2000/XP and Windows CE, along with high-speed
switched Ethernet (maxNET) communications and
Distributed Processing Units (DPUs), to give an open
Architecture and reliable control system.
The maxDNA DDCMIS follows a multi-level hierarchy.
The lowest or first level interacts with the actual plant by
acquiring the parameters/status, and issuing the actuating
signals/commands.
This is done by the I/O modules. The second level
performs closed loop control and open loop control,
which is accomplished through execution of atomic
blocks by DPU in maxDNA. The operator console or the
Operator’s Workstation (OWS), and the supervisory
console or the Engineer’s Workstation (EWS), are at the
third level. At the highest level, called Enterprise
Management Network, engineers and managers have
access to the entire system database.
MAXDNA software runs on popular Microsoft
platforms. The attractive features of maxDNA software
for the benefit of the engineer or operator are:-
1. High level object-oriented programming in Graphical
User Interface(GUI)
2. Wide selection of standard library functions
3.Provision for user-defined multi-function expandability
4. User flexibility in assigning inputs/outputs
5. Unique address for I/O signals

Figure shows network connections of maxDNA systems.

.
 CONCLUSION

I hereby affirm that the information given in this report is

true to the best of my knowledge and is based on the
training undergone at C&I department .This report fulfils
the basic requirement under vocational training for
undergraduates.
I again affirm that this report is fully made by
me, Vidya Sagar and information provided is true to the
best of my knowledge and belief.