Mr.

S
Electronics and Communication Engineering
Maulana Azad National Institute of Technology,
Mr. S. J. P

IN PANT INTE!NS"IP

Submitted by,
Mr. SAJA MA"ES"#A!I
$.Tech %&'(()&'(*+
Electronics and Communication Engineering ,e-artment
ana Azad National Institute of Technology,




Guided by,
Mr. S. J. Patha. / Mr. ,. !. Mantri
INTE!NS"IP !EP0!T %&'(1+
!EIANCE ,A"AN2 T"E!MA P0#E!

,e-artment
ana Azad National Institute of Technology, $ho-al

!EIANCE ,A"AN2 T"E!MA P0#E! STATI0N,,A"AN2
P!E3ACE

This Report has projected !EIANCE IN3!AST!2CT2!E T,. as one of
the most efficient companies of India. The historical background of
!EIANCE IN3!AST!2CT2!E T,. highlights its gradual establishment.
It starts with an introduction to company profile.
Main purpose of undergoing this Internship is to make a student
familiar with the industrial atmosphere and get accumulated with
different Psychology at the employees that survive in an industry. For
an aid and to solve our ueries we have our training supervisor in an
industry. For an aid to solve our ueries we have or training supervisor
who guides us and e!plains the reuired solutions. I" here by narrate a
brief picture of what I have done" observed" learnt during my Internship
tenure through this report.

AC4N0#E,5EMENT



I am e!tremely thankful for having been able to receive this Internship
opportunity at the ,ahanu Thermal Po6er Station %,TPS+, which is a
unanimous part of !eliance Infrastructure td.

I would like to e!press my sincere gratitude and thank Mr. Sudhir J.
Patha. # Mr. ,inesh !. Mantri for continuous support and motivation
during my internship period.

This internship program provided me a lot of opportunities and
e!posed me to interaction with different sets of people. My sincere
thanks also to Mr. S. S. $or.ar, Mr. P. N. ,esai, Mr. ,.M. 5a7ali, Mr.
Shon 5aon.ar, Mr. Saura8h Patil, Mr. Nitin -hadtare, Mr. ouis
3ernandez, Mr. M. S. 9elas.ar, Mr. !oshan Patil and team mates for
accepting me under their department and guiding me throughout my
Internship program.

I also wish to thank my Institute" Maulana Azad National Institute of
Technology, $ho-al for encouraging me to join this internship program.

$ast but not the least I wish to thank the highly dedicated and
motivated staff at %TP& for making me a part of their team and making
my internship an e!clusive e!perience.


A$ST!ACT

This report gives an insight into the Internship undertaken by me at
%'(')* T(+RM'$ P,-+R &T'TI,) .%TP&/" %ahanu" Thane.
Main purpose of undergoing this in plant Internship and training is to
make a student familiar with the industrial atmosphere and get
accumulated with different psychologies at the employees that survive
in an industry. For an aide to solve our ueries we have our training
supervisor who visits at intervals.
I" here by narrate brief picture of what I have done" observed" learnt
during my training tenure through this project report.

C0NTENTS

(. 0rganization Profile
&. Introduction
:. "istory of ,TPS
1. Technical S-ecifications
*. Tur8ine / Au;iliaries
<. $oiler / Au;iliaries
=. Cycles in ,TPS
>. Cali8ration of Instruments
?. ,istri8uted ,igital Control System %,,C+
('. Programma8le ogic Control %PC+

Conclusion


0rganization Profile

Reliance Infrastructure" a part of Reliance 0roup" is India1s largest
infrastructure company with turnover of over Rs.23"456 crores and
market capitali7ation of over Rs89"936 crores as on March :2"
8626.Reliance Infrastructure $imited is India;s leading utility company
having presence in across the value chain of power business i.e.
0eneration" Transmission" %istribution" +P< and Trading and the largest
infrastructure company by developing projects in all high growth areas
in infrastructure sector i.e. Roads" (ighways" Metro Rails" 'irports and
&pecialty Real +state.
Their presence spans across three verticals=
+ngineering" Procurement and <onstruction
+nergy
Infrastructure
+P< offers a single point solution to the e!ecution of power plants
including project engineering" procurement" construction #
commissioning for its clients.
The core competency in +nergy e!tends to generation" transmission"
distribution and trading.
Infrastructure has a significant presence in the construction of roads"
metros" airports and real estate.
INT!0,2CTI0N

' thermal power plant is a power station in which the prime mover is
steam driven. -ater is superheated" turns into steam and spins a
turbine which drives an electrical generator. 'fter it passes through the
turbine" the steam is condensed in a condenser and recycled to where
it was heated> this is known as the Rankine cycle. ?arious designs of
thermal power stations e!ist due to the different fuel sources
.coal@gas@waste etc./. &ome prefer to use the term energy center
because such facilities convert forms of heat energy into electricity.
&ome thermal power plants also deliver heat energy for industrial
purposes" for district heating etc. in addition to delivering electrical
power.



"istory of ,TPS

2. The land development commenced in the year 2556.
8. The main plant contract got finali7ed in the year 2552.
:. *nit A2 was synchroni7ed on 4th Banuary 2553 and unit A8 was
synchroni7ed on 85th March 2553.
9. The power station commercially commenced its operation in 2554.
3. %ahanu thermal power plant was taken over by Reliance group in
866:C69.
4. %TP& is a 366M- plant and is located at 286 km from Mumbai over
:32.3D hectors.
E. It is divided into two units of 836 M- each.
D. %TP& has complete automatic control # monitoring of the turbine"
boiler and au!iliaries by %igital %istributed <ontrol" Monitoring and
Information &ystems .%%<CMI&/.
5. It has one of the tallest chimney in the country .8E3.: meters/.
26. It has all modern euipments like F0% .flue gas desulphuriser/.



Technical s-ecification

Type of &tation FThermal
&tation <apacity C366M- .8!836 M-/
Fuel C266G coal
<oal &ource F
Indian <oalCF 0rade
'ustralian <oalC' 0rade
Transportation F by Rail # &hip
<onsumption F 8.34 million tons@year assuming D666 hrs
<olony 'rea F 266 (ectors
In water source F 'rabian &ea
<onsumptive Reuirement F E4666 m: @hr
'sh %isposal F -et 'sh %isposal system
<himney (eight F 8E3.: m
Make up water C H :G
Plant 'rea F :32.3D (ectors
'sh %isposal 'rea F :E6 (ectors


Tur8ine and Au;iliaries
Tur8ine@
The steam from boiler is taken to turbine section where heat energy is
converted into mechanical energy. In turbine section the steam passes
through three stages of turbine which are (PT" $PT" IPT etc.
i. "PT %high -ressure tur8ine+
The steam is passed to high pressure turbine where the pressure is
about 236kg@s.cm. ,utput of (PT goes to reCheater .R(/. The
temperature of steam is increase in R(" so efficiency gets improves.
ii. IPT %intermediate -ressure tur8ine+
From reChater steam is passed to IPT in order to further increase the
efficiency.
iii. PT %lo6 -ressure tur8ine+
The steam from IPT is passed to $PT" which is further connected to
condenser. The si7e is (PTHIPTH$PT. The si7e of $PT is greater in order
to provide larger surface area" which helps in effective # fast cooling of
steam.
i7. Condenser
' vacuum is maintained in condenser so as to e!tract the low pressure
steam from $PT. )ow this steam gets reCconverted to water.
In condenser there is cooling system which converts steam into water.
This water is collected in hotwell and then passed to $P( through
condenser e!traction pump .<+P/.

Tur8ine au;iliary@
It consists of=
2. %eaerator
8. <+P .condenser e!traction pump/
:. IFP .boiler feed pump/
(. ,eaerator@
From $P( the water goes to deaerator. The capacity of deaerator is
store water is about si! times that of flow of steam. The function of
deaerator is to remove gases dissolved in water. From deaerator water
goes to (P( through boiler feed pump.
Ielow the deaerator there is F&T .field storage tank/. The discharge
pressure of F&T is about 8.3 kg@s.cm. From deaerator water goes to
(P( through boiler feed pump.

&. CEP %condensate e;traction -um-/=
There are two <+Ps i.e. <+PC' # <+PCI> at a time only one is in
operation while the other is in &tandby. Its function is to e!tract the
condensate from the hotCwell and pump it to the further stages.
There are two 266G capacity <+P per unit. The <+P is of the <entrifugal
canister vertical type pump driven by electric motor. Its suction is from
condenser hotCwell and the discharge goes to $P heater through drain
coolers and gland steam cooler.
Problem of <+P pressure switch" so it is calibrated in lab and system
made to normal.

:. $3P %$oiler 3eed Pum-+@
The function of IFP is to pump water to a drum where pressure is
about 236kg@s.cm. The pressure is called discharge pressure. The
booster pump is provided at the suction to avoid cavitation. The
discharge boiler feed pump goes to (P(.

$oiler / Au;iliaries
I. $oiler
It is enclosed pressure vessel. Ioiler can be regarded as a number of
interconnected heat e!changers arranged in such manner that heat
available by burning of fuel is transferred to convert water into steam
in most efficient manner.
ii. Process@
<ombustion of fuel which is evaporation process.
iii. In-ut@
<oal@oil" water" air i.e. chemical energy is converted to heat energy by
creation of fire ball. (eat generated is transferred to water circulating
inside water wall tubes.
i7. 0ut-ut@
Flue gas" ash and steam. (eat transferred in boiler by conduction"
convection and radiation.
,TPS $oiler s-ecification@
a/ Manufacturer= I(+$ <.+ design
b/ Ty-es= )atural circulation" balanced drafts" double pass single drum"
single reheat direct pulveri7ed coal fire.
c/ $oiler design -ressure= 2D8kg@cm8
d/ $oiler tem-erature= 396J<
e/ $oiler designation= 3896K22364" 255K298
f/ Ty-e of firing= tilting tangential
g/ Total heating surface= 894E6mL:
h/ 3urnace height= :5.543m

II. $oiler Au;iliaries
a/ <oal Mills
b/ P' fan .Primary air fan/
c/ F% fan .Forced draft fan/
d/ I% fan .induced draft fan/
e/ +&% .electrostatic precipitator/
f/ 'P( .'ir preCheater/
g/ +conomi7er


a+ Coal mills
The main fuel used for generation of power in plant is coal. In plant
there are three coal mill 'I" <%" +F" out of which only two in service at
a time while third remain in stand by condition. <oal" which is supplied
by coal handling plant" is send to the coal mills via bunker after being
crushed into small pieces .inside various crushers/ in coal mills.
There is a shell .containing steel ball/ which is continuously rotating. In
this shell coal is entered and due to continuous rotation #collision of
coal particles with steel balls" the coal get finally pulveri7ed .i.e. it is
converted in powdered form/ this pulveri7ed coal is sent to furnace.
8+ PA fan
There are two P' fans in each unit. P' fan gives primary air which is
used to transfer the pulveri7ed coal from coal mill to the furnace.
'nother function of P' fan is to remove moisture content present in
coal so that it is completely dried which helps in complete combustion
of coal. Its speed is normally 2366 rpm
c+ 3, fan
There are two F% fans in each unit. F% fans are used to raise the
pressure of air necessary to overcome draft losses in flow passages of
steam boiler plant.
It supplies air necessary for fuel combustion by taking directly
atmospheric air. F% fan raises the pressure of ambient air and delivers
it to boiler furnace through air preCheater .'P(/. The pressure rise is
about 866CD66 mm-c.
d+ I, fan
The I% fan is provided for e!traction of flue gases. There are two I% fans
for each unit. The I% fan e!tracts flue gases from electrostatic
precipitator .+&P/ and passed through chimney. 'nother function of I%
fan is to maintain negative pressure inside furnace. Its normal speed is
2666 rpm.
e+ Electrostatic -reci-itator %ESP+
From furnace flue gases pass through two passes" passC' # passCI"
these two passes are given to +&P. In +&P" there are two electrode
plates .M?+ # C?+ E6Nv/ with dielectric medium between them. The ash
is deposited on this plate. Then this ash is removed from these plates
byhammering and ash gets deposited into hopper. ,utlet of +&P have
two passes 'I # <% are then combined # this is given to I% fan.
?enture tubes are connected to hopper" which suck the ash. In hopper
there is a heater" which maintains the temperature of ash to avoid
solidification of ash.
f+ Air Pre)"eater %AP"+
Iefore transferring this pulveri7ed coal to furnace" the coal is preC
heated with the help of hot air of air preCheater. The 'P( is also used to
heat the air generation from F% fan.
There are two preCheaters 'P(C' # 'P(CI. In 'P( there is tri sector"
which rotate continuously. In one sector there is flue gas coming from
boiler. The temperature flue gas is :66J< to 966J<. The second sector
consists of air coming from F% fan. -hen this tri sector rotates flue gas
comes in place of P' air. This interaction causes an increase in
temperature of air.
g+ Economizer
It is used to heat water by utili7ing the heat of e!haust flue gases before
leaving through the chimney. It improves the efficiency of boiler. In this
plant economi7er plain" drainable" non streaming. The economi7er is
located in boiler rear gas pass below the rear hori7ontal superCheater.
The flue gas temperature is around 932J<. In the economi7er" the heat
is recovered from the flue gas to heat the feedCwater.


Cycles in ,TPS
(. Steam Cycle@)
It consists of the following=
I. The $oiler@
The boiler has many fine tubes which run around its circumference.
This arrangement is called waterCwall. These tubes consists of boiler
feed water which is heated by the furnace heat to form steam. Thus the
heated tubes contain feed water # steam. These tubes open up inside
the boiler drum. The boiler drum has arrangement for separating steam
from water. This steam is then given to the super heater for further
heating. The separated water which is collected in the boiler drum
flows down to the bottom ring header via si! down comer tubes. This
water is then recirculates in the waterCwalls naturally due to density
difference between steam and water and the cycle continues.
II. Su-er "eater %S"+@
The super heater is placed inside the furnace. It superheats the steam
output of boiler drum. It consists of the following super heaters=C
2/ Radiant super heater .R&(/
8/ (ori7ontal super heater .(&(/
:/ Platen super heater .P&(/
9/ Final super heater .F&(/
The super heater gives out two outputs to (PT .i.e. main steam right
.M&CR/ # main steam left .M&C$//.
III. "PT %"igh Pressure Tur8ine+@
It is smaller in si7e since the steam which enters the (PT has a high
operating pressure and lower volume so it reuires less space for
e!pansion i.e. to produce work. It has two inputs M&CR # M&C$ which
provide superheated" pressuri7ed steam to rotate the turbine. ' single
line steam output .<R(/ is taken from (PT # given to the ReCheater.
I9. !e)"eater %!"+@ (<(<
The ReCheater is placed inside the furnace. It reheats the steam from
single line output of (PT. The temperature is raised to avoid premature
wetness in the last stages of turbine. This steam line is called <R( .cold
reCheat/. The reheater gives out two outputs to the IPT i.e. (R(CR #
(R(C$ .(R(Ohot reheat/.
9. IPT %Intermediate Pressure Tur8ine+@
It is medium in si7e as when steam enters the IPT it has less pressure
and more volume than that at (PT so it reuires more space for
e!pansion. It has two inputs (R(CR # (R(C$ which provide reCheated
steam to rotate the turbine. The output of the IPT is directly given to
the $PT.
9I. PT %o6 Pressure Tur8ine+@
It is large in si7e as the steam which enters into $PT has low pressure
and a large volume and hence reuires a large space for e!pansion. The
steam once utili7ed in $PT is then directly dumped into the <ondenser.
&. Condensate Cycle@)
It consists of the following=
I. <ondenser=
In this closed vessel the steam from $PT is cooled by bringing it in
contact with tubes containing <- .<ooling -ater/ # thus it condenses
to water .condensate/. ?acuum is maintained in the condenser due to
the condensation of steam and also to ensure efficient e!traction of
steam from the Turbine. This water is collected in a hotCwell at the base
of the condenser from where it is e!tracted and reused.
II. <+P .<ondensate +!traction Pump/=
?. %< .%rain <ooler/=
It is a heat e!changer which is used to heat the condensate.
?I. $P( .$ow Pressure (eaters/=
These are heat e!changers which use steam e!tractions from the $P
turbine to further heat the condensate.
?II. %eaerator $evel <ontrol &tation=
It is an assembly of valves used to control the level of the condensate
inside the %eaerator.
:. 3eed 6ater Cycle@)
It consists of the following=
I. %eaerator=
It removes dissolved air # other soluble gases from the condensate
through heating.
II. IFP .Ioiler Feed Pump/=
It is used to pump the feed water .condensate from the %eaerator/ into
the Ioiler. There are two IFPs i.e. IFPC' # IFPCI and only one is
operational at a time.
III. (P( .(igh Pressure (eaters/=
These are heatCe!changers which use steam e!tractions from the IP
turbine and <R( to preheat the feed water.
I?. +<, .+conomi7er/=
This is an array of tubes which utili7e the wasteCheat from flue gases for
heating the feed water. Thus it economi7es the heat of the flue gases.
?. FR& .Feed water Regulating &tation/=
It is assembly of valves used to control the level of feed water inside the
boiler drum.
There are two <+Ps i.e. <+PC' # <+PCI> at a time only one is in
operation while the other is in &tandby. Its function is to e!tract the
condensate from the hotCwell and pump it to the further stages.
III. 0&< .0land &team <ooler/=
It is a heat e!changer which heats the condensate from <+P using
dumped sealing steam from the Turbine.
I?. <P* .<ondensate Polishing *nit/=
It removes corroded metal" metal particles from abrasion # other fine
impurities from the condensate.

Cali8ration of Instruments
<alibration is a comparison between measurementsC one of known
magnitude or correctness made or set with one device and another
measurement made in as similar a way as possible with a second
device. The device with the known or assigned correctness is called the
standard. The second device is the unit under test" test instrument" or
any of several other names for the device being calibrated.
?arious types of Instruments are described belowC
Position Transmitter)
It is used to transmit the valve stem position in the form of electronic
feedback signal of 9C86 m' range. This signal is given to the process
control room for further analysis and control. It is R?%T .Rotational
?ariable %ifferential Transformer/ type. The variation in valve stem
position rotates the cam which is connected to the mechanical linkage.
This in turn moves the solenoid to vary the output current. The span
and range trimpots are provided to vary the output current as per
reuirement.


Inter-osing !elay)
Relays used as interposing relays are generally necessary because the
circuit.s/ being switched have voltages and@or currents which can1t be
accommodated by the Pdriving relayP. For e!ample" let1s say the relay of
a P$< can only accommodate 6.3' at 886 ?'<" but the solenoid which is
to be connected to the relay reuires 2.8' at 886?'<. In this case" an
interposing relay with contacts rated for operation at 2.8' at 886 ?'<
would be used as an interposing relay PbetweenP the P$< relay and the
solenoid. The coil of the interposing relay should reuire less voltage
and current than the driving relay is rated for" and the contacts of the
interposing relay must be rated to handle the reuirements of the load
.solenoid" light" contactor" motor" etc./.
I to P %current to -ressure+ Con7erter)
' Qcurrent to pressureR converter .I@P/ converts an analog signal .9 to
86 m'/ to a proportional linear pneumatic output .: to 23 psig/. Its
purpose is to translate the analog output from a control system into a
precise" repeatable pressure value to control pneumatic
actuators@operators" pneumatic valves" dampers" vanes" etc. Its force
balance principle is a coil suspended in a magnetic field on a fle!ible
mount. 't the lower end of the coil is a flapper valve that operates
against a precision ground no77le to create a backpressure on the servo
diaphragm of a booster relay. The input current flows in the coil and
produces a force between the coil and the flapper valve" which controls
the servo pressure and the output pressure.
Pneumatic 9al7e Positioner)
It is motion balanced type. It has two input signals .2. 'ir supply signal
of 86 psig # 8. <ontrol signal which comes from I@P converter/ and an
output signal which is given as input to diaphragm case in order to
position the valve.
Tem-erature S6itch)
' temperature switch comes with a Pt266 platinum sensor" sensor tip>
which in relation to the temperature changes its electrical resistance.
The electronics of the temperature switch alters the resistance in a
clear electronic signal .9C86 m' analog signal/ thus switching on or off
signal transmission.
Tem-erature 5auge)
The most widely used temperature gauge at %TP& is argon gas filled
temperature gauge.
The measuring method of an inert gas filled thermometer is the
e!pansion of gas in a closed system. <hanges in temperature of the
process to be measured create a change of pressure in the measuring
system" which is translated on the dial into read out of the correct
temperature. This type of thermometer is available as direct mounting
and as capillary thermometer.
Solenoid 7al7e)
' solenoid valve is an electromechanical valve that is controlled by an
electric current. The electric current runs through a solenoid" which is a
wire coil wrapped around a metallic core. ' solenoid creates a
controlled magnetic field when an electrical current is passed through
it. This magnetic field affects the state of the solenoid valve" causing the
valve to open or close. &olenoid valves are used to transport gases or
liuids and have a wide variety of applications" including irrigation"
sprinkler systems and industrial uses.
Pressure S6itch)
It is a switch which accepts pressure signal as input signal to turn on or
off. It mainly consists of a diaphragm and a micro switch. The micro
switch has )ormally ,pen contact # )ormally <lose contact. -hen
appropriate pressure is applied on diaphragm" it presses against the
micro switch and ), contact becomes )< while )< contact becomes
),.
Thermocou-le)
' thermocouple is a device consisting of two different conductors
.usually metal alloys/ that produce a voltage" proportional to a
temperature difference" between either ends of the two conductors. It
operates on &eebeck effect.
Thermocouples are a widely used type of temperature sensor for
measurement and control and can also be used to convert a
temperature gradient into electricity. They are ine!pensive"
interchangeable" are supplied with standard connectors" and can
measure a wide range of temperatures. In contrast to most other
methods of temperature measurement" thermocouples are selfC
powered and reuire no e!ternal form of e!citation. It is mostly used at
places where temperature is high .2666C2366 J</ and where high
accuracy is needed.
!esistance Tem-erature ,etectors)
Resistance Temperature %etectors .RT%s/" also called resistance
thermometers" are sensors used to measure temperature by
correlating the resistance of the RT% element with temperature. Most
RT% elements consist of a length of fine coiled wire wrapped around a
ceramic or glass core. The element is usually uite fragile" so it is often
placed inside a sheathed probe to protect it. The RT% element is made
from a pure material whose resistance at various temperatures has
been documented. The material has a predictable change in resistance
as the temperature changes> it is this predictable change that is used to
determine temperature.
RT% and Thermocouple are the instruments used in %TP& for
temperature measurement.
RT% is used for less than E66CD66 < while Thermocouple is used for high
temperatures more than 2666 <. Iut" RT% gives more accurate readings
than Thermocouple.

,istri8uted ,igital Control System %,,C+
Power Plant operation is very speciali7ed field and reuires close and
simultaneous monitoring of various plant euipment like boiler"
turbine" generator" IFP etc. and associated au!iliaries to maintain the
continuous availability of unit as well as to ensure safe and efficient
operation of these euipment for such control and monitoring purpose
a lot of plant data .analog inputs/ in the form of physical measurements
and status of euipment .digital inputs/ are needed. In older days
control system being treated as separate@independent system using
their own dedicated conventional hardware" using conventional display
devices like indicators" recorders" conventional push button and
auto@manual stations.


The major features of %%<=
2. The computational tasks are shared between the processors" the
system capability is greatly enhanced.
8. The system is more fle!ible.
:. If any microprocessor fails" the implications are not catastrophic" as
only portion of system@process will get affected.
9. +asy to change@modify the software.
3. The units in the system can become standardi7ed.
4. The inter linking of distributed units by a data highway means they
can be distributed over a wide area.
E. The availability of color monitor based operating station provides
information and guidance to the operator for his actions.
D. <ontrol rooms are simplified. 'll information;s are available in <RT;s.


PC %Programma8le ogic Control+
' programmable logic controller is designed for use in an
industrial environment.
P$< 're Microprocessor based device
P$< is designed for multiple inputs and outputs
<apable to implement control functions such as &euential
operation" timing" counting" etc.
P$< programming can be of instruction type and ladder type. In
%TP&" ladder type of programming is used.
Programming may be of provision" protection or interlock type.





C0NC2SI0N


The Internship Program at !eliance Infrastructure imited, ,TPS
%,ahanu Thermal Po6er Station+ at ,ahanu !oad, Thane" which is one
of wellCestablished organi7ation in India" has aided me in not only
gaining practical e!perience but also to adopt the industrial
environment and procedures.
It has also taught me the importance of effective time management in
the life of a student and the difference between theoretical knowledge
and actual practical e!perience that I gained in the industry. It has also
provided me with an opportunity to put into use some of the
knowledge that I have gained during my education as a student of
Maulana Azad National Institute of Technology, $ho-al.