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bnnkjk dghhjjkkll adfgghjjk adffghjk serhhjkkk sdfghjkkkk sdfgjjkk sdfgjkk sfdfhhjkkkllllfvghhjnjmk wrtabcdefghijklmno ON PANIPAT THERMAL POWER STATION (A UNIT OF H.P.G.C.L., HARYANA)

Submitted in partial fulfillment of the requirement for the award of Degree in Instrumentation and control

SUBMITTED TO: Mr. Himanshu Gupta XEN/ Training INDEX

SUBMITTED By: -_______________

S.NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Contents Certificate Acknowledgement Introduction of P.T.P.S Three Major Inputs to Power Station Familiarization with plant Layout Diagram Centum System DCS Instrumentation used in C&I Control Loop Transmitter O2 Analysers Alarm Annunciation

13.

UPS & SER

CERTIFICATE I ____________, submit my training report detailing the work done during 6 weeks training at P.T.P.S, Panipat. I have written this report from the sources that have been fully acknowledged. Name Roll No Division Date of Commencement Date of Completion : : : : : C & I-III

Ms. _____________ has worked under my supervision during training period. I have read this report, it meets our expectations and it accurately reflects work don e by him.

Er.Amod Jindal XEN./ C&I-III P.T.P.S, Panipat.

Er.Shishpal Singh AEE/ C&I-III P.T.P.S, Panipat.

ACKNOWLEDGEMENT The present report would not have been possible with out the help, I have receiv ed from various quarters. I shall be failing in my duty if don t acknowledge the h elp and guidance from these sources. I extend my special thanks to Er. Himanshu Gupta, XEN Training division and Er A

mod Jindal, XEN/C&I-III and Er. Shishpal Singh, AEE/ C&I-III for their benevolen t guidance and kind cooperation throughout my training and for compl eting this project report. I also convey my special thanks to all other staff me mbers. This guidance has helped me a lot in power plant familiarizations and und erstanding various plant processes. Last but not least, I am thankful to all for their sincere effort during placeme nt.

________________ Roll No._________

INTRODUCTION Panipat Thermal Power Station is situated at a distance of about 12 km. from Pan ipat. It is on Panipat- Jind Road near village Assan. This plant has been constr ucted in five stages as given below: Stage 1 : Stage 2 : Stage 3 : Stage 4 : Stage 5 : Total generation capacity Unit -1 Unit -2 Unit -3 Unit -4 Unit -5 Unit -6 Unit -7 Unit -8 110 M.W. 110 M.W. 110 M.W. 110 M.W. 210 M.W. 210 M.W. 250 M.W. 250 M.W. 1360M.W.

THREE MAJOR INPUTS TO POWER STATIONS 1) Water : Water has been taken from near by Yamuna Canal. This wat er is lifted by raw water pumps and is sent to clarifier to remove turbidity of water. The clear water is sent to water treatment plant, cooling water system an d service water system. The water is de-mineralized (DM) by water treatment plan t. The DM water is stored in condensate storage tanks from where it is used in b oiler. 2) Fuel Oil : The fuel oil used is of two types: (a) (b) Low sulphate high stock oil (LSHS) High speed diesel oil (HSD)

The high speed diesel oil reaches the power station through the lorry tankers. T he oil is stored in large tanks for the future use in the boiler. Heavy oil is stored in storage tanks in oil storage yard and is conveyed to the front through a set of pumps and strainers. The whole length of piping from the boiler front in stream traced to maintain the temperature and hence its fluidity so that it can freely flow in the pipelines. 3) COAL : The coal reaches the plant in the railways wagons. The unloading of coal is done mechanically by tilting the wagons by tippler. The coa l is sent to the coal storage yard through the conveyor belts. The crushed coal from store is sent to the mill bunkers through conveyor belts. The air which takes away the coal dust passes upward in to the classifier where the direction of flow is changed abruptly. This causes t he coarse particle in the air coal stream to finer coal dust along with the prim ary air leaves the classifier onto the coal transport piping from where it goes to nozzle. Pulverized coal obtained from coal mill can not be burnt directly. GENERAL WORKING DIAGRAM

FAMILARIZATION WITH PLANT BOILER: Boiler is a device used for producing steam. There are two types of boilers: a) Fire tube boiler

b)

Water tube boiler

Here, boiler used is of water tube type. In the boiler, heat energy transfer tak es place through tube walls and drum. The gases lose their heat to water in the boiler or superheated. The escape heat is used to heat the water through economi zer. ID and FD fans are used to produce artificial draught. The fuel oil is used to i gnite the boiler and pulverized coal is lifted from the coal mills by PA fans. TURBINE: Turbine is form of heat engine in which available heat energy in the form of ste am is converted into kinetic energy to rotate the turbine by steam expansion in suitable shaped nozzles In Thermal Power Station there are reaction turbines. The turbine consists of three stages: high pressure, intermediat e pressure and low pressure. Steam enters the turbine at 350oC with maximum allo wable temp. of 545oC. Cold reheat steam goes to boiler, reheated at 540oC, then fed to medium pressure parts of the turbine. Then after cooling it goes to hot w ell. GENERATOR: The shaft is coupled with generator. The generator converts the kinetic energy o f the rotating shaft to electric energy. Field windings are excited by D.C. powe r using exciter. Shaft of generator rotates at 3000 rpm speed.

CONDENSER: In condenser, the water passes through various tunes and steam passes through a chamber containing a large number of water tubes (about 20000). The steam gets converted into water droplets, when steam comes in contact with w ater tubes. The condensate is used again in boiler as it is dematerialized water and 5-6 heats the water, which was in tubes, during the process of condensation . This water is sent to cooling tower. COOLING TOWER: It is a structure of height 110m designed to cool the water by natural draught. The cross sectional area is less at the center just to create low pressure so th at the air can lift up due to natural draught and can carry heat from spherical drops. The upper portion is also diverging for increasing the efficiency of cool ing tower. Hence it is named as natural draught cooling tower. ELECTROSTATIC PRECIPITATIOR: It is an electronic device, which removes the ash particles from the smoke throu gh furnace of boiler. It helps in prevention of air pollution. It works on the p rinciple that a charged particle is attracted towards opposite charge. When the fly ash comes between the opposites charged plated it gets charged and is attrac ted towards the plates and then collected from the plates by the discharging par ticles. ASH HANDLING PLANT: Ash is not discharged as such to pollute the land, air and water, but slurry of

ash is made in ash handling plant and this slurry is dumped in the wasteland, ke pt for the purpose. SWITCH YARD: Switchyard is the area, which feed the grid supply to the station transformer an d fees the grid by the power generator by the unit. The power supply control is administrated here and the units consumed and supplies are recorded in the contr ol room. The connections of 220KV BUS to the station transformer is done by usin g the isolated and gas filled circuit breakers. ELECTRICITY FROM COAL: Electric power generation takes place in the following steps: 1. Coal to steam 2. Steam to mechanical power 3. Switching and transmission COAL TO STEAM: The boiler burns pulverized coal at rates up to 200 tons per hour. From the coal store, fuel is carried on a conveyor belt and discharged by means of a coal tip per into the bunker. It then falls through a weigher into the coal-pulverizing m ill where it is ground to a powder as fine as flour. Air is drawn from the top of the boiler house by the forced drau ght fan and passed through the air pre-heaters to the hot air duct. From here so me of the air passes directly to the burners and the remainder is taken through the primary air fan to the pulverizing mill, where it is mixed with the powdered coal, blowing it along pipes to the burners of the furnace. Here it mixes with the rest of the air and burns with great heat. The boiler consists of a large nu mber of tubes and the heat produced raises the temp. of the water circulating in them to create steam, which passes to the steam drum at very high pressure. The steam is then heated further in the super heater and fed through outlet valve t o the high pr. cylinder of the steam turbine. When the steam has been through the first cylinder (high pr.) of the turbine, it is returned to the repeater of the boiler and reheated before b eing passed through the other cylinders(intermediate and low pr.) of the turbine , From the turbine the steam passes into a condenser to be turned back into wate r condensate . This is pumped through feed heaters where it may be heated to about 250oC to the economizer where the temp. is raised sufficiently for the condensat e to be returned to the lower half of the steam drum of the boiler. The flue gases leaving the boiler are used to reheat the condens ate in the economizer and then pass through the air pre-heaters to the electro-s tatic precipitator. Finally they are drawn by the induced draught fan into the m ain flue and to the chimney.

STEAM TO MECHANICAL POWER: From the boiler, a steam pipe conveys steam to the turbine through a stop valve and through control valves that automatically regulate the supply of steam of th e turbine, Stop valve and control valves are located in a steam chest and a gove rnor, driven from the main turbine shaft, operates the control valves to regulat e the amount of steam used. Steam from the control valves enters the high pr. cylinder of th e turbine, where it passes through a ring of stationary blades fixed to the cyli nder wall. These act as nozzles and direct the steam mounted on a disc secured t

o the turbine shaft. This second ring turns the shaft as a result of the force o f the steam. The stationary and moving blades together constitute a stage of the t urbine and in practice many stages are necessary. The steam passes through each stage in turn until it reaches the end of the high pr. cylinder and in its passa ge some of its heat energy is charged into mechanical energy. The steam leaving the high pr. cylinder goes back to the boiler for reheating and is returned to the intermediate pr. cylinder. Here it passes t hrough another series of stationary and moving blades. Finally, the steam is taken to the low pr. cylinder each of whic h it enters at the center flowing outwards in opposite directions through the ro ws 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 te m. fall and it expands. The turbine shaft rotates at 3000 rpm at 50 Hz. The turb ine shaft drives the generator to generate alternating current. When as much energy as possible has been extracted from the stea m it is exhausted directly to the condenser. This runs the length of the low pr. part of the turbine and may be beneath or on either side of it. From the conden ser, the condensate is pumped through low pr. feed heaters by the extraction pum p, after which its pr. is raised to boiler pr. by the boiler feed pump. It passe d through further feed heaters to the economizer and the boiler for recon versio n into steam.

SWITCHING AND TRANSMISSION: The electricity is usually produced in the stator windings of the large modern g enerators at about 25,000 volts and is fed through terminal connections to one s ide of a generator transformer that steps up the voltage 132000, 220000 or 40000 0 volts. From here conductors carry it to a series of three switches comprising an isolator, a circuit breaker and another isolator. The circuit breaker, whi ch is a heavy-duty switch capable of operating in a fraction of a second, is use d to switch off the current flowing to the transmission lines. Once the current has been interrupted the isolators can be opened. These isolate the circuit brea ker from all outside electrical sources. From the circuit breaker the current i s taken to the bus bars-conductors, which run the length of the switching compou nd and then to another circuit breaker with its associated isolates before feedi ng to the grid. Three wires are used in a three-phase system for large power trans mission. The center of the power station is the control room. Here engineers mon itor the output of electricity, supervising and controlling the operation of the generating plant and high voltage switch gear and directing power to the grid s ystem as required.

CENTUM CS DCS In unit-6 for Station C&I , Centum CS DCS supplied by M/S YBL has been installed . CS (Concentral Solutions) is a Basic Concept coined for Yokogawa System Busine ss. CS also Implies Customer Satisfaction. Centum System was Introduced by Yokog awa in 1975 and through series of innovations and improvements in Centum Systems Centum CS was introduced in the World Market in 1993. The Centum CS system com plies with the following international standards;1. CSA Standard C22.2 No 1010-1 (North America) 2. CSA Standard EN61010-1 (Europe) 3. EMC Standard (Europe) Power Plant comes under the category of Process Control and Automation Industry . Electronic Computers were first introduced in the Process Control Field in 196 0s. Digital Control Technology developed in the following years and Computers sl owly took over the whole Process Control Automation. The Centum CS system featur es Integrated Operation, Open Network Architecture, Control Stations with RISC C PU and other advanced functions. The system can be configured flexibly from smal l scale to full scale depending upon the plant to be controlled. The System Conf iguration for Unit-6 is as below:1. ICS (Information Command Stations) 2. FCS (Field Control Stations) 3. HICS (Hyper Information Command Station) 4. ACG (Advanced Communication Gateway Unit) 5. Peripherals a) Serial Printers b) Color Hard Copy Unit c) Laser Printer 6. Analog marshalling Cabinets 7. Digital Marshalling Cabinets 8. Relay Cabinets 9. Software a) System Software 6 No. 1 No. 1 No. 10 No.

1 No 1 No. -

3 No

6 No 10 No 4 No

b)

Application Package

10. Network 1. ICS (Information Command Station) :In total 6 No ICSs have been installed. 5 Nos are being used by Shift Engineers for Operation and Monitoring of the Plant and 1 No is being used by the Shift Ch arge Engineer for Supervision. The ICS is a high performance Human Interface use d for Control & Monitoring of Plant Operations. It does this by gathering all of the required information . Process Variables, Set Points, Measured Values, Control Parameters, Alarm Status etc. Here in the Unit-6 Desktop ICSs have been used. The ICSs are of high Performance and equipped with Duplexed Hard Disk. It is called Mirrored Disk Co nfiguration. The Data in each Hard Disk is exactly the same. If one disk fails t he Operation and Monitoring can be continued with the other disk. 2. FCS (Field Control Station) :The Field Control Station is also termed as Integrated Control Station (IE C) i.e. I Instrumentation Control E Electric Control C Computer Functions FCS is composed of FCU, NIU, Connecting RIO Buses, Nodes: and I/O modules. (I) FCU (Field Control Unit): The FCU is the microprocessor based Computing Unit of the FCS. Its Process Co ntroller uses RISC Chips to Ensure High Speed Processing and Excellent Function ality. It is fitted with Dual Redundant Processors and Power Supplies. The Pai r and Spare design of Control Processors offers functions which are not possibl e in conventional standby redundancy design. The standby processor card executes control computations at all times in synchronization with the current processor card. Thus control continuity is maintained and in the event of glitch, Contr ol of the Active Processor card is instantly transferred to the Hot Standby Pr ocessor Card thus unaffecting the plant operation.

(II) NIU (Node Interface Unit) : The NIU communicates with FCU via redundant RIO Buses . The unit consists of a communication card and dual redundant power supply cards. (III) Nest : The nest houses Input/Output Modules. For different type of modules different type of nests are used. (IV) I/O Modules : I/O modules are 16 channel Microprocessor Based Cards. The different types of I/O modules are: Analog I/O Modules Digital I/O Modules RTD Modules Thermocouple Modules.

a) b) c) d)

The signals from field through marshalling cabinets are connected to I/O modules which in turn communicate with NIU and to FCS through RIO bus and then through V-net to ICS etc. (V) RIO Bus:

The RIO (Remote Input/Output) bus is a communication bus that is dual redundant connecting the FCU and the Nodes. The RIO Bus allows a nest to be changed without suspending the FCU s control functions or breaking data communication with another nest. RIO Bus Specifications: Item Specifications Transmission route Twisted pair or optical fiber cable Type Bus type Redundancy Dual redundant Communication rate 2 Mbps 3. HICS(Hyper Information Command Station): HICS can act as ICS as well as EWS (Engineer Work Station). The HICS performs s upervisory functions i.e. modification of control drawings, auto loop schemes , interlock protection schemes, logic charts, sequence tables. It is connected to the N/W through ACG via E Net. 4. ACG (Advanced Communication Gateway Unit):An ACG is a unit for communicating with the Supervisory Computer System. This unit is used for acquiring and setting data to FCS by the supervisory comp uter. 5. Peripherals: The peripherals devices i.e. Serial Printers, Color hard Copy Unit, Laser printe r are used for taking trend, history and alarm printouts. 6. Analog Marshalling Cabinets: Analog Marshalling Cabinets act as an Interface between System Cabinets and anal og field inputs and outputs . The field I/Os are connected to marshalling cabine ts and through interfacing boards reach to system cabinets via prefab cables. 7. Digital Marshalling Cabinets: Digital Marshalling Cabinets act as an Interface between System Cabinets and dig ital field inputs and outputs . The field I/Os are connected to marshalling cabi nets and through interfacing boards reach to system cabinets via prefab cables. 8. Relay Cabinets: Relay Cabinets act as an Interface between System Cabinets and Electrical MCC fo r driving electrical motors, valves and dampers. Relay cabinets also provide req uisite isolation between DCS and other system digital field inputs and outputs. Start/Stop Commands for electrical devices like HT/LT motors, Valve and dampers, solenoids etc from System Cabinets to Electrical MCCs are routed through Relay Cabinets . 9. Software : The system is designed on Unix Platform with GUI (Graphic User Interface) as X Windows. Some application programming has been done in the Yokog awa Propritary User C. The Unix is from different sources : a) AT & T Unix b) Yokogawa Proprietary Unix c) HP Unix The ICSs run on AT&T Unix and Yokogawa Proprietary Unix and HICS on HP Unix.. Be sides these System Softwares, Application Software Packages like ICS Basic Softw are and Optional Packages are loaded in ICSs depending upon the use to which the ICS is subjected to. In the HICS Centum CS application package is loaded. All t hese application packages are Yokogawa Proprietary Packages. Apart from these so ftwares some additional application packages like performance calculations and

time sync, developed in the User C, are also being used in the Unit-6. 10. Networks: Two Networks have been used with the Centum CS. V Net: V Net is a real time control network for connecting an FCS to other stations such as an ICS and ACG. V net is capable of performing dual redundant communications at speeds as fast as 10 Mbps. This network employs a link transmission system as well as a much appreciated read/write communication system and message communication system. V Net Specifications: Item Specifications Transmission route Coaxial or optical fiber cable Type Bus type Redundancy Dual redundant Communication rate 10 Mbps E Net : E Net is information LAN which connects an ICS to other ICS in the syste m. With E-Net the ICS performs following functions. a) Display of the trend record data. b) Display of the graphic panel c) Printing via the printer or colour hard copy unit. d) Loading the engineering data created with engineering functions. E Net Specifications: Item Specifications Transmission route Coaxial cable Type Bus type Communication rate 10 Mbps

CENTUM SYSTEM ARCHITECTURE

45

1 2 3 INATOR FOR V-NET 4 INATOR FOR E-NET

V-NET E-NET END TERM END TERM

INSTRUMENTATION IN THERMAL PLANTS 1. INTRODUCTION Thermal Power Stations employ a great number of equipments performing number of complex processes the ultimate aim being the conversion of chemical energy into Electricity. In order to have stable generating conditions, always a balance is maintained between the Heat in-put and Electricity output plus losses. But the b alance is frequently disturbed due to (i) grid disturbance external to the proce ss and machines, (ii) the troubles in the process itself or (iii) the trouble in the equipments. When the balance is disturbed, all the process variables deviat e from their normal valves thus creating the necessity for the following:i) Instruments : To measure and indicate the amount of deviations. To correct the deviation and bring back : To warn about the excessive

ii) Automatic Control: the system to normal. iii) Annunciation deviations, if any.

iv) Protection : To isolate the equipments process from dangerous operating conditions caused due to such excessive deviations.

2.

POWER STATION INSTRUMENTATION:

2.1 The proportionate cost of instrumentation during seventies was about 2.3 to 2.5% of the total cost of boiler, turbine and their Auxiliaries. When the un it size were 60/100MW turbine But this has become about 7% when the unit size h as become 210MW and is expected to reach about 10-12% of even higher in the nea r future for the same capacity units. This increase in instrumentation cost is d ue to i) Increase in installed capacity making the units to operate at higher parameter for economics reasons. ii) New innovations, improvements, modernization of instruments and equipments. iii) Expected change in the duty cycles of the boiler and turbine faci litating two shift operation, quick run up etc. iv) Improved awareness among the personnel about the utility of the instrume nts.

2.2 TYPE OF INSTRUMENTS: The emphasis is only on the process instrumentation measuring the physical quant ities such as temperature, pressure, level flow etc. The other type of instrum ents are the electrical instruments, measuring electrical quantities such as cur rent, voltage etc. The different type of instruments normally in use are given b elow:

2.2.1

INDICATORS

Indicators are of two categories local indicators are self contained, self opera tive and are mounted at site. The remote indicators are used for telemeter purpo ses and mounted in the centralised control room or control panel. The indicators both local and remote are some times provided with signaling contacts where eve r required. The remote indicators depend upon electricity, electronics, pneumati c or hydraulic system for their operation and accordingly they are named. The in dicators can be classified as analogue or digital on the basis of final display of the reading. Indicators are available for single point measurement or can be connected to a number of points through a selectors switch or automatic scanner system. This multipoint system considerably reduces the number of instruments wi thout affecting the measurements much. 2.2.2 RECORDERS

Recorders are necessary where ever the operating history is required for analyzi ng the trends and for any future case studies or efficiency purposes. Recorders can be of single point measuring a single parameter or multipoint measuring a nu mber of parameters by a single instrument. Multipoint recorders are again catego rized as multipoint continuous recorders/multipoint dot recorders. The multipoi nt dot recorders select the point one after the other in sequence where as the c ontinuous recorders measure simultaneously all the points.

3.

PRESENTATION OF INFORMATION

Enormous amount of information measured and received from the various parts of t he plants/process are to be presented to the operators giving appropriate import ance to each one. In order to have an easy and effective presentation, the infor mation s are generally grouped into the following three groups. 3.1 Vital information which are required by operators at all times for th e safe operation of the plant. These information s are presented through single po int indicator recorder, placed on the front panels. Main steam pressure, tempera ture condenser level, vacuum, drum, furnace pressure etc. are some such paramete r. 3.2 The second group of information s are generally not vital under the nor mal operation of the plant. But they become vital whenever some sections of the plant start malfunctioning. Such needs are met through multipoint indicators/rec orders placed in the front panels. Temperature and draft across the flue gas pat h bearing temperatures of the motors of fans etc. are some such examples. 3.3 The last group of information s are not required by the operators but for the occasional need of the efficiency engineers. These information s are given by recorders mounted on back panels or local panels. D.M. make up quantity, fue

l oil flow quantities etc. are some examples.

4.

CODING OF INSTRUMENTS

In order to distinguish the parameters required from the other instantly, coding for shape of instrument face is being adopted. This is an useful practice and i nvariably finds place in power stations. However coding may vary as per the prac tices of the organization. A general approach could be as below: Level instruments Horizontal edgewise Horizontal edgewise Circular.

Temperature instruments Pressure instruments 5. -

SELECTION CRITERIA OF INSTRUMENTS

Instrument engineers are required to work in close association with the system d esign requirement as well as the equipment design requirement in selecting instr uments and sensing systems. After deciding the capacity of the Thermal Power sta tion the designs of boiler turbine and auxiliary equipments such ass mills, pump s, fans Deaerator, feed heaters etc. are taken up. Based on the design of the ma in and auxiliary equipments, the parameters values for efficient and economic op eration at determined load are specified. The instruments and system design engi neers decide the location for the measurement of various parameters such as leve l, pressure, flow differential pressure, temperature and other parameters based on the system design and layout conditions. Then the instruments engineers select the appropriate instruments influenced by the following factors: i) ii) iii) iv) v) vi) vii) viii) Required accuracy of measurement Range of measurement The form of final data display required Process media Cost Calibration and repair facilities required/available Layout restrictions Maintenance requirements/availability

6. CONCEPT OF INSTRUMENT IN THERMAL POWER STATION The concepts of instrumentation are that: 1. Instruments should be independent for their working. 2. The total instrumentation should be inter-dependent to each other in ass essing the process condition. 3. Instrumentations should be sufficient to provide adequate information s to the operators for :

a) Cold start of the unit b) Warm/hot start of the unit c) Shut down both planned and emergency shut down. 7. POWER STATION INSTRUMENTATION The process conditions and the equipment conditions are to be assessed by the op erators from the information s received from the various instruments. The instrume nts and range vary widely as per the process media. The following section deals with these instruments. The inter dependence and inter relations of these instru ment play very significant roll in the stability and the efficiency of the heat balance. 7.1 TEMPERATURE MEASURING INSTRUMENTS

Accurate measurement of temperature is required to assess the material fatigue, heat balance, heat transfer etc. The measurement ranges varies from ambient temp eratures where as air inlet to F.D fan is measured, to 2300 to 1400 degree centi grade inside the furnace zone. Temperature measurement is to be made in many med ias such as, water/steam, oil (Fuel oil and lubricating oil), air, flue gases, h ydrogen gas, metal temperatures of bearing, turbine top and bottom, generator wi nding and cores, SD.H. tube metal etc. Filled system thermometry such as mercury in glass, mercury in steel, vapour fil led or gas filled are used for local indication of temperature, bimetallic therm ometers can also be used for local indication. The selection of thermometer depe nds upon the range of the temperatures to be measured. These instruments are ava ilable with electrical contacts for setting up annunciation and protection syste m wherever required. Resistance thermometers or thermocouples are used as primary sensors in remote m easurement of temperature depending upon the range. Resistance thermometers are of platinum and copper resistance type. Platinum resistance thermometers are cal ibrated to have resistance value of either 46 ohms or 100 ohms at 0 degree centi grade. While copper resistance thermometers have a value 53 ohms at 0 degree cen tigrade. The secondary instruments used in conjunction are cross coil indicators or electronic bridges. These instruments indicate temperature by measuring the value of resistance which changes with the change in temperature. Resistance the rmometers are used generally up to 300 degree centigrade. Above 300 degree centi grade, thermocouples are used as primary sensors. The common type of thermocoupl es used in thermal power plant is Chromel-Alumel or Chromel-copel type depending upon the temperature. Iron-Constantan is another thermocouple in use. The secon dary instruments used in thermocouple sensors are pyrometric mill volt meters or electronic potentiometers. Null balance method is used for the very accurate me asurement of mill volts generated by thermocouples sensing the process temperatu re. The electronic bridges and potentiometers can be either indicators or indica tor cum recorders with alarm protection contacts and with remote transmission fa cilities. 8. PRESSURE MEASURING INSTRUMENTS The pressure measurement in Thermal Power Station ranges from 1 Kg/Cm2 (nearly) at condenser to hydraulic test pressure of the boiler. Here again many medias ex ist such as steam/water, lubricating oil, fuel oil, air, flue gases, hydrogen et c. For local indication of pressure, mainly two types of pressure gauges are emp loyed in the plant. 1. Bourdon Type 2. Diaphragm Type

1. BOURDEN TYPE GAUGES: These gauges are employed for the measurement of higher pressure. These gauges a re employed for the measurement of higher pressure Burdon gauges measure the dif ference between the system pressure inside the tube and atmospheric pressure. It relies on the deformation of a bent hollow tube of suitable material which, whe n subjected to the pressure to be measured on the inside (and atmospheric pressu re on the outside), tends to unbend. His moves a pointer through a suitable gear -and- lever mechanism against a calibrated scale as shown in fig. (A) 2. DIAPHRAM TYPE GUAGES;In such gauges, there is a ease or decreases which in and is shown on the scale. ype of gauges and so these e gauges there are U type. diaphragm which expends or contracts as pressure incr turn is converted to angular movement of the pointer Diaphragm gauges are more sensitive than the former t are used to measure low pressure. In addition to thes

If Z is the difference in heights of fluid columns in the two limbs of the U tub e (fig b-1 and b-2) and d the density of the fluid and g the acceleration due to gravity, then from the elementary principle of hydrostatics, the gauge pressure Pg is given by Pg = Z.d.g. N/m2 The pressure measured by any type of pressure gauge is known as gauge pressure a nd the pressure relative to a perfect vacuum is called absolute pressure. Absolute Pressure= Gauge Pressure + Atmospheric pressure. Remote measurements of pressure are done by transmitters either electronic or pn eumatic coupled with a secondary instrument indicator/ recorder. Many varieties of transmitters are in use. In these transmitters the mechanical movement of sen sing elements such as bourdon, bellows, diaphragm etc. due to the pressure, caus es an electrical property to change such as current. Voltage, resistance capacit ance, reluctance inductance etc. which is utilized as a measure of pressure in t he secondary instruments. The secondary instruments are either indicators or r ecorders which may incorporate signally contacts. 9. LEVEL MEASUREMENT Level measurement is generally carried out as differential pressure measurement. In power stations, level measurement in open tanks such as D.M. storage tank an d fuel oil and lub oil tanks and is closed tanks such as deaerator, condenser hot well, boiler drum and L.P. & H.P. heaters are to make. Gauge glasses and f loats are used for local indication of levels and the transmitters used for meas uring the differential pressures are used along with the secondary instruments f or remote level measurements. The measurement of boiler drum level poses many pr oblems because of varying pressure and temperatures and many computations and co rrections are to be made in order to get correct levels. A recent development in this area is the `HYDRA STEP'. Though it is very costly but it improves the acc uracy and reliability of this measurement. Other problem area is the solid level measurement where the coal bunker levels and dust collector hopper level are re quired. In both these cases continuous level measurement is not possible. Howeve r fairly reliable and accurate provisions are available to indicate the extreme levels on either directions (low or high). The nucleonic level gauges or the cap acitance and resistance type sensors serve in this area very well. 10. FLOW MEASUREMENT Flow measurement of solids, liquids, liquids and gases are required in Thermal P

ower Stations. Though the liquid flow measurements are made very accurately, the gas flow measurement cannot be done accurately whereas steam flow measurement r equires density correction under varying pressures. The air and flue gas flow me asurement suffer accuracy and reliability due to variation in pressure, temperat ure, duct leakage, dust accumulation etc. The solid flow measurement is very dif ficult and only a rough idea is arrived at about the P.F. flow through different ial means. In power stations flow measurements are based on differential Princip les. Differential Pressure are created by placing suitable throttling devices in the flow path of the fluids in the pipes/ducts. The throttling devices are suit ably selected depending upon the media, flow quantity etc. from among orifice, v enturi, flow nozzle ball tube etc. The differential pressure developed across s uch sensing devices in proportional to the square of the flow quantity. The diff erential pressure is measured by the devices discussed in 8 with additional squa re root extraction facilities. 11. ANALYTICAL INSTRTUMENTS Apart from the above there are few quantity measurements necessary in thermal po wer generating plants of high capacities. These include feed water quality mea suring instruments such as conductivity PH dissolved oxygen, and sodium instrume nts, steam quality measuring instruments such as conductivity, silica and HP a nalyzers. The combustion quality is assessed by the measurement of the percentag e of oxygen, carbon monoxide or carbon dioxide in the flue gases. The purity of hydrogen inside in the generator housing is measured by utilizing the thermal co nducting capacity of the hydrogen gas. The water and steam purity is measured as the electrolytic conductivity by electronic bridge method in which one arm from the electrodes of conductivity cell dipped into the medium. The volume percenta ge of oxygen in combustion gases are made utilising the paramagnetic properties of oxygen. The carbon mono oxide percentage is measured by the `ABSORPTION OF EL ECTROMAGNETIC RADIATION' Principle. Both these gas analysers require elaborate s ampling and sample conditioning system resulting in poor reliability and availab ility of these measurements. Recent developments in these fields have brought ou t on line `in situ' instruments for these two parameters where the problem of sa mpling is dispensed with. The `ANALYTICAL INSTRUMENTS' as the above instruments are called had been the neglected lot so far in the power stations. But now the authorities seem to think their importance for the process. 12. DATA ACQUISITION AND DATA LOGGING The conventional central control room is rather a cumbersome system. Large numbe r of instrument must be observed to know what is happening inside the plant. The Data Acquisition simplifies this job by collecting all the measurements trans mitted from the process, converting them into digital term and storing in the me mory bank. The periodic logging of parameter by the operators are dispensed with after the introduction of data acquisition system. Which prints out the periodi c conditions on predetermined time intervals. All the important measurements at one time are printed along a row. Data loggers thus reduce the use of graphical recorders. Since data logging gives too many measurements at a time, it cannot b e easily digested by the control staff. Now data reduction systems are finding t heir use where only the process quantity deviated from normal value is shown. 13. VISUAL DISPLAY UNIT (V.D.U.) Visual display units go along with the data acquisition system. In V.D.U. pre-s elected schemes, flow paths with parameters, running alarm conditions etc. can b e brought on color television tubes on demands. This gives the life picture of t he happening inside the plant making the operation easy and effective. TESTING AND CALIBRATION OF PRESSURE GUAGES: 1) Comparison method 2) Dead weight method

1.

COMPARISION METHOD

In this method inside the tubes there is oil. There are two outlets on the tube, on one outlet, master gauge (accurate) is applied and on the other end the gaug e to be checked or calibrated is applied. Valve No.1 and 2 are opened. Oil from chamber connected to valve 1(Chamber 1 say) goes to chamber connected to valve 2 (say chamber 2). Now tighten the valve 1 so that on tightening valve the oil sh ould not reenter chamber 1 rather goes to the two gauges. Now valve 2 is steadi ly tightened so that the pressure shown by both the gauges should be exactly equ al. In this way the gauge can be checked or calibrated. 2. DEAD WEIGHT METHOD

This method is more accurate than the former one. The basic principle of its wor king is almost same as that of former one. Here instead of employing a master ga uge, we use weights placed on a pan. The master gauge may be wrong but weights a re always correct so this is more accurate method. CONTROL SYSTEMS There are two types of control loops in use in PTPS Unit-8 in the FCS:Open Closed Following modes are available for control: Auto Manual Cascaded The closed loops use PID controllers and open loops use AND, OR, SR flip-flops e tc. The closed loops use: Process Variable (PV) - the actual value of the parameter. Set Value (SV) - the desired value of the parameter. Manipulated Value the value used to send out control signal. Difference Value it is the difference b/w PV and SV. Of all the ICS, HICS available, only HICS has the capacity to alter any control logic loaded in the FCS in live as well as shut down mode. Various indications are used in control system to indicate low, high, very low, very high values of parameters with different colors. To understand the various modes and loops involved, three examples of real plant control system are explained in the following pages. Example I: Statement: - The level of water in the boiler drum has to be maintained within s pecified levels to ensure that boiler water tubes do not starve due to lack of w ater or cause damage to the turbine due to the excess of water in drum overflowi ng into the turbine.

EXAMPLE II: Statement: - The feeder speed has to be kept under control to maintain the level to coal in the mill. Excess of this quantity would lead to overloading of coal mill and inadequate quantity would lead to under utilization of the resources.

As can be seen from the figure, there are three PIDs involved in the control sys tem. The first one is in auto mode and the other two are in cascaded mode. Casca ded mode is the one in which the set value is decided by another stage and need not be decided by the user. The transmitter in the field indicates the coal level in DP. Two readings are ta ken and the better of the two as decided by the FCS is taken as SV for first PID . The level of differential riving end of the mill is user, therefore, decides two PIDs used to control pressure between the driving end of the mill and non-d used as the set value for the first PID auto mode. The this SV. The MV of this PID gives the SV for the other the feeder rate. Thus they are in cascaded mode.

EXAMPLE III: Statement: - Many types of equipment in the power plant need certain other equip ments in a specified condition to ensure their smooth running. This example cove rs Forced Draft Fan (FDF). For running FDF, there are certain permissive and certain protections. The vario us permissive and protections form inputs for an AND gate as shown in figure. Th us it is an open loop control system. Another way of classifying permissive and protections is to classify them into i nitial permissive denoted by FDIL and those leading to tripping of plant denote by FDTT. FDIL (Permissive) comprises of :Inlet damper should be closed. Lubricating oil pressure should be O.K. At least one ID fan should be running; otherwise the flue gases would not escape . Temperature of the NDE and the DE ends of the fan should be within limits. FDTT (Protections) comprises of :Bridge temperature should not be very high. Lubricating oil pressure should not be very low. For the drum to be controlled, eitherThe speed of the motor should be increased or decreased according to the require ment of water level, or The interlock fixed before the drum be closed to decrease water flow or opened t o increase water flow and is opened to let excess water flow out or closed to st op out-flow. The designer of the control system has to decide which of the above mentioned st rategies he will employ. Suppose he chooses the later one, then, Process Variable = Level + Net Water Flow + Net Steam Flow

Units of variables in PV :Level - mm Net water Flow - tonnes/hr. Net Steam Flow - tonnes/hr.

The best way to make units of all the quantities involved is to convert them to their percentages:NAME RANGE PV PERCENTAGE LEVEL -300 to 300 47.3 (47.3+300)/(300+300) NET WATER FLOW 0 to 900 30 30/900 NET 0 to 750 636.4 636.4/750 PV = 57.88 + 3.33 + 84.85 = 146.06 The SV is fed to the PID controller build for the purpose. CALIBERATION: - If pressure (1-150 kg/cm) has to be measured, then 4mA stands for 1 kg/cm and 20 mA stands for 150 kg/cm. The intermediate ones are measure accordi ngly, say 75 kg/cm for 12 mA. For measuring differential pressure, the pressure on both sides of diaphragm cau ses spindle to move giving output in current. For measuring flow, square root is calculated in microprocessor card. Earlier transmitters used to employ concept of change in capacitance due to move ment of diaphragm to measure pressure. One of the most appreciated aspects of this instrument is the calibration of the se devices can be done from computer in remote control room by HART protocol or BRAIN protocol.

I/P CONVERTER If any control signals has to be sent to the field by the FCS and has implementa tion to be done by pressure, then this instrument requires I/P Converter whereby current is converted into pressure. In short, it is issued for controlling pneu matic valves. Pneumatic valves are used to control opening and closing valves pa rtially, which is difficult to control through electric motors. The pressure exe rts force on a diaphragm connected to a piston, which moves down closing the val ve. WORKING: - A constant supply of air of pressure of range 0-7 kg/cm is maintained at one terminal. The input signal is of range 4-20 mA. When signal of 4 mA is re ceived, the lid moves for enough from the nozzle to let an output pressure of 020kg/cm given out through the output pipe. When a signal of 20 mA is received, th e lid moves near enough to the nozzle to let air pressure of 1 kg/cm flow through the outlet. For intermediate current values, pressure of range 0.2-1 kg/cm is gi ven out for exerting pressure.

INTRODUCTION OF SOME INSTRUMENTS USED IN PLANTS The instruments used in plant as stated above is divided into two categories: (1) Processing instrument (2) Recording & indicating instrument Mainly transmitter is used as processing instruments recorder, pen type recorder , indicator, temperature scanner & digital electrolytic conductivity monitor is used as recording and indicating instruments. RTD & thermocouple is used as sens or. Brief details of these instruments are given below and its application also: TRANSMITTER : There are different types of transmitters are used. They all are uses for differ ent purposes. Mainly it is used to measure pressure. This can be done with the h elp of sensing elements as diaphragm or below etc. It is also used for flow and level measurement. For this, orifices or other equivalent devices are used in co nduction with the sensing element. This is a primary instrument and depends upon the displacement of the sensing el ement when subjected to pressure or differential pressure. Electrically it is a differential transformer. The primary coil is connected to a stabilized A.C. sup ply. The two secondary windings are differentially connected.

Operating Principle : The I/P differential pressure (D.P.) is converted into electrolytic capacitance in the detecting unit. The variation of electrolytic capacitance is then amplifi ed and computed in the electronic circuit to transmit O/P current. It can displa y output unit to be tones or kg/cm or mm. Working : When pressure has to be measured, the medium passes through a diaphragm whose mo vement causes spindle to move in a magnetic field and EMF is generated. Thus, tr ansmitter converts pressure into current. This current is converted into milli a mperes by the microprocessor card.

Note: All the measurements have to be converted to 4 to 20 milli amperes as the computers in control room can accept current of this range only. Normally all in struments have microprocessor cards installed for this purpose. OXYGEN ANALYSER The steam water analysis station uses oxygen analyzer. It is designed to measure the net concentration of Oxygen in an industrial process i.e. the oxygen remain ing after all fuels have been oxidized. This equipment is permanently positioned within the exhaust duct. No sampling is required. It measures oxygen by reading the voltage developed across a heated electro-chem ical cell consisting of small Ythria-stabilized, zirconium disc. Both sides of d isc are coated with porous metal electrodes. It must be operated at a requisite temperature, which is supplied initially by a battery. EMF generated is given by EMF=KT log10 (P1/P2) +C Where, P2 is the partial pressure of oxygen in the measured gas on one side of the cell. P1 is the partial pressure of oxygen in reference gas on the other side C is cell constant. K is arithmetic constant. The method used for measurement is that when the cell is at operating temperatur e and there are unequal oxygen concentrations across the cell, oxygen ions will travel from high partial pressure of oxygen to lower partial pressure side of th e cell.

ALARM ANNUNCIATION SYSTEM The alarm annunciation system is a very useful system in the working of Thermal Power Plant that indicates any abnormal process condition. As one enters the cab in of engineers operating the ICSs, one can see the huge panels containing displ ay windows of this system.

These systems work extremely well in noisy environment. It uses RS-485 communica tion protocol. The circuits use high speed CMOS VLSI Micro Controller Technology . Alarm logic and output do not responds to signals of less than 10 milli second s. They use high impedance devices leading to low power consumption. E.g.:- PROCON Alarm annunciations system PAL 2100. The system is modular based (plug-in-type) which makes fault diagnosis easy. LED s are provided on each module to indicate card failure and input failure. Variou s modules in the system are:-Processor Module -Input module Repeat Relay Module -Power Supply Rack System -Intelligent Lamp Box According to the urgency associated with the annunciation system, the volume and the shrillness of the hooter is set. Whenever any series of annunciation comes, a button is available to detect the first one that propped up, being the root c ause of the trouble. Also different colours of lamps are used to indicate the le vel of urgency, e.g.-Red, Yellow and Orange.

UNINTERRUPTED POWER SUPPLY There are certain equipments, which cannot be shut down in case of power failure . For these vital equipments, UPS system is established which ensures uninterrup ted power supply. The components of UPS are:-Rectifier and battery charger -PWM inverter utilizing IGBT as switching devices -Electronic Static Bypass switch -Microprocessor based data monitoring and logging system With LCD display. Operation: The controlled rectifier is converting 3 phase AC into ripple free D C. Rectifier has to handle with Battery Charger power and inverted rated power s imultaneously. Battery charger decides battery charging modes as per battery requirement. PWM inverter controls O/P related parameters under distortion etc. The inverter is s ynchronous with bypass sources if frequency is within tolerable limits. Battery Operations: Battery provides power till end cell voltage reaches to 1.75 V/cell and inverter trips due to battery low conditions. It starts replenishing, the moment main power resumes.

Static Bypass Operation: If inverter fails, power is continued through static by pass. The transfer from inverter to static bypass and vice-versa takes place.

Specifications: Rectifier Load Power Factor Battery Voltage Ripple without Battery -1% - Full Wave - 0.7 lag to unity within KVA & KW rating - 360 V (DC)

SEQUENCE EVENT RECORDER AND MASTER LOCK A machine dedicated to the very purpose of recording occurrence of any event wit h the resolution of one millisecond is installed in Unit called the Sequence Eve nt Recorder. Thus, if any trouble pops up, a chain of disturbances follow. This device comes most handy in such situations to decipher the epicenter of the prob lem the only drawback the Unit-8 is that it has a S.E.R with a resolution of 1 m illisecond. To make sure that all the computers in the Unit work with the same clock time an d any delays due to aging of computers, all the processors are connected to the Master Clock connected to the Global Positioning System. This master clock sends synchronization pulses to the processors which updates their timings every seco nd or every minute or every hour as per the requirement.

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