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PROJECT REPORT ON INDUSTRIAL AUTOMATION AT KTPS

(18-06-2015 TO 11-07-2015)

ACKNOWLEDGEMENT
The Training opportunity I had with KOLAGHAT THERMAL POWER PLANT
(WBPDCL) was a great chance for learning and professional development.
Therefore, I consider myself as a very lucky individual as I was provided
with an opportunity to be a part of it. I am also grateful for having a
chance to meet so many wonderful people and professionals who led me
though this internship period. Bearing in mind previous I am using this
opportunity to express my deepest gratitude and special thanks to the GM
of KTPS MR. TAPAS KUMAR PATRA who in spite of being extraordinarily
busy with her/his duties, took time out to hear, guide and keep me on the
correct path and allowing me to carry out my project at their esteemed
organization and extending during the training. I express my deepest
thanks to Mrs Susmita Basak, HR manager KTPS for taking part in useful
decision & giving necessary advices and guidance and arranged all
facilities to make life easier. I choose this moment to acknowledge his/her
contribution gratefully. I will also thank my teammates Madhumainty
,Debtanu, Aindrila, Lucy ,Moumita for their support in this whole training.

PROJECT REPORT ON INDUSTRIAL AUTOMATION AT KTPS


(18-06-2015 TO 11-07-2015)

CONTENT
1. INTRODUCTION OF A THERMAL POWER PLANT
1.1
1.2
1.3
1.4
1.5
1.6
1.7

PAGE NO

Theory of Thermal Power Station


Line diagram of a Power Station
Overview of Kolaghat Thermal Power Station
General layout of KTPS
Efficiency of a Thermal Power station
Advantages and disadvantages of a thermal power plant
Major thermal power plant in India

UNIT OPERATION OF A THERMAL POWER STATION

2.1Coal preparation in TPS


2.2Boiler operation
2.3Steam turbine operation
2.4Generator operation
2.5Condenser operation
2.6 CT operation (cooling and recycling)
2.7 Ash handling plant operation
2.8 Grid operation

2. BOILERS
3.1 Definition of boiler

3.1.1 Function
3.1.2 Working
3.1.3 Quality
3.2 Types of boiler
3.3 Boiler systems
3.4 working of water tube boiler in tps
3.5 Boiler drum
3.6 Steam flow
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3.7 Economiser
3.8 water tubes
3.9 super heater
3.10 reheater
3.11 Steam generator control
3.13 Steam generator efficiency
3.14 Ash handling system
3.15 deration

3. STEAM TURBINE
3.1 Definition of steam turbine
3.2 Type of steam flow
3.3 Type of steam turbine
3.4 Cylinder arrangement in steam turbine
3.5 Turbine losses
3.6 General layout of a steam turbine in a power plant
3.7
Steam turbine Equipment & Related Auxiliaries
3.7.1 Turbine rotor
3.7.2 Turbine Casing
3.7.3 Turbine coupling
3.7.4 Turbine bearings
3.7.5 Turbine sealing system
3.8 Turbine supervisory instrument& system control
3.9 Turbine governing system

4. CONDENSER
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8

& CIRCULATING WATER SYSTEM

Definition of condenser
Working of a condenser
Condenser in power cycle
Condenser associative equipment
Condenser tube cleaning
Water usages in thermal power plant
A brief idea of a CW system
Cooling water and ACW System

5. COAL HANDLING PLANT


5.1
5.2
5.3
5.4
5.5
5.6
5.7

Definition and Objective of CHP


General layout of CHP
Operation cycles in CHP
Sections of CHP
Operation cycle of coal unloading
Layout of KTPS coal handling plant
Equipment used in CHP
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6. ASH

HANDLING PLANT

6.1 Definition of ash handling system


6.2 General diagram of ash handling plant
6.3 Requirement of ash handling plant
6.4 Parts of ash handling plant
6.4.1 Bottom ash handling system
6.4.2 Coarse ash handling system
6.4.3 Air preheater ash handling system
6.4.4 Fly ash handling system
6.4.5 Ash slurry disposal system
7. DM WATER SYSTEM AND CHEMICAL LABOATORY
7.1 Sources of water in DM plant
7.2 Composition in water
7.3 Importance of water treatment
7.4 Stages of treatment
7.4.1 Pre-treatment Plant
7.4.2 Demineralization plant

9. GENERATOR AND GENERATOR AUXILIARIES


9.1 Development of large Generator
9.2 basic components of a generator

9.3 working principle of Synchronous Generator


9.4 Rating of Generator in KTPS
9.5 Generator cooling system

10. RELAY SWITCHGEAR AND CIRCUITBREAKER


11. ELECTICAL CONTROL ROOM AND SWITCHYARD
11.1 Control panel
11.2 PLC room and single line diagram of KTPP switchyard
11.3 components in switchyard

1. INTRODUCTION OF A THERMAL POWER PLANT

PROJECT REPORT ON INDUSTRIAL AUTOMATION AT KTPS


(18-06-2015 TO 11-07-2015)
1.1 Thermal power generation plant or thermal power station is the most
conventional source of electric power. Thermal power plant is also referred
as coal thermal power plant and steam turbine power plant.
The theory of thermal power station or working of thermal power station is
very simple. A power generation plant mainly consists of alternator runs
with help of steam turbine. The steam is obtained from high pressure
boilers. Generally in India, bituminous coal, brown coal and peat are used
as fuel of boiler. The bituminous coal is used as boiler fuel has volatile
matter from 8 to 33 % and ash content 5 to 16 %. To increase the thermal
efficiency, the coal is used in the boiler in powder form.

1.2 Line Diagram of Power Plant

1.3

OVERVIEW OF KOLAGHAT THERMAL POWER STATION

Kolaghat Thermal Power Station is a major thermal power


station in West Bengal. It is located at Mecheda , approx. 55 km from
Kolkata in the Purba Medinipur district. The power plant is operated
by West Bengal Power Development Corporation Limited.
The power plant has six units of 210 MW each for a total capacity
of 1260 MW. The units were commissioned in two stages during the
period of 1984 to 1995.
STAGE

UNIT NO

INSTALLED

DATE OF

CAPACITY(MW

COMMISSIONIN

210

SEPT-1990
5

STATUS

OP

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1
2
210
MAR -1986
OP
1
3
210
OCT-1984
OP
2
4
210
APR-1995
OP
2
5
210
MAY-1991
OP
2
6
210
JAN-1994
OP
The ABL or BHEL make boiler of single drum ,water tube natural
circulation type with superheater and reheaters.The maximum conditions
2
evaporation of the boiler is 700 T/hr at 136 kg/ cm

and 500 c ,the

maximum reheater flow is 605 T/hr.The water cooled furnace


walls,superheaters,reheaters and economisers being self-contained
construction and are suspended from supporting structure.
The BHEL make C-210-130 model 210 MW turbine is condensing tandem
compound ,three cylinder ,impulse type machine , with nozzle governing
and regenerative feed heating. The double flow LP turbine incorporates a
multi exhaust baumen stage in each flow.
The rated output of the generator is 210 MW with main steam parameters
before emergency stop valve being 130 ata and 535 C. steam flow at
valve wide open operation is 670T/hr .the IP and LP rotors are connected
by a semi-flexible coupling.
The condenser cooling system is a closed system .There nos 331/3%
capacity ,C.W pumps of 9500

M 3 /hr. capacity and intake pump house is

located in river Rupnarayan. There is also a acw pump for machine cooling
of 2500

/hr capacity . In cooling there are 9 cooling fan systems for

each unit. The capacity of make-up water pump is 2000 M

/hr capacity

are located in cooling towers.


A close cycle DM water cooling system is there.that system keeps
supplying for the boiler system and machine auxiliaries (bearings, seal
dil,valves) .DM plant has two stage. Stage 2 has automated system.
The coal requirements of the 3 units about 9000T/day are met by coal
handling plant by coal conveyor chain capacity of 800 T/hr.
Each 210 MW generator is connected to 220 KV grid through a 235 MVA
/Y step up transformer. For auxiliaries UAT is connected in T network of
16MVA capacity .In shut down 31.5 MVA reserve Transformer has been
installed .
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It has also an efficient DC system for excitation and control of many
electrical drives of 415 and 220 V.
Now ABB will install a new system in stage 3 for better handling and
commissioning and ATRS system will be installed shortly.

1.6 ADVANTAGES AND DISADVANTAGES OF THERMAL POWER PLANT

Advantages: 1) Economical for low initial cost other than any generating
plant.
2) Land required less than hydro power plant.
3) Since coal is main fuel & its cost is quite cheap than petrol/diesel so
generation cost is economical.
4) There are easier maintenance.
5) Thermal power plant can be installed in any location where
transportation & bulk of water are available.

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Disadvantages: 1) The running cost for a thermal power station is
comparatively high due to fuel, maintenance etc.
2) Large amount of smoke causes air pollution. The thermal power station
is responsible for Global warming.
3) The heated water that comes from thermal power plant has an adverse
effect on the lives in the water and disturbs the ecology.
4) Overall efficiency of thermal power plant is low like less 30%.
2. UNIT OPERATION IN TPS
2.1 coal preparation in TPS:
Most thermal stations use coal as the main fuel. Raw coal is transported
from coal mines to a power station site by trucks, barges,
ships or railway cars. Generally, when shipped by railways, the coal cars
are sent as a full train of cars. The coal received at site may be of different
sizes. The railway cars are unloaded at site by rotary dumpers or side tilt
dumpers to tip over onto conveyor belts below. The coal is generally
conveyed to crushers which crush the coal to about 34 inch (19 mm) size.
The crushed coal is then sent by belt conveyors to a storage pile.
Normally, the crushed coal is compacted by bulldozers, as compacting of
highly volatile coal avoids spontaneous ignition.
The crushed coal is conveyed from the storage pile to silos or hoppers at
the boilers by another belt conveyor system.
2.2 Boiler operation: The boiler is a rectangular furnace about 50 feet
(15 m) on a side and 130 feet (40 m) tall. Its walls are made of a web of
high pressure steel tubes about 2.3 inches (58 mm) in diameter.
Pulverized coal is air-blown into the furnace through burners located at the
four corners, or along one wall, or two opposite walls, and it is ignited to
rapidly burn, forming a large fireball at the centre. The thermal
radiation of the fireball heats the water that circulates through the boiler
tubes near the boiler perimeter. The water circulation rate in the boiler is
three to four times the throughput. As the water in the boiler circulates it
absorbs heat and changes into steam. It is separated from the water
inside a drum at the top of the furnace. The saturated steam is introduced
into superheat pendant tubes that hang in the hottest part of the

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combustion gases as they exit the furnace. Here the steam is superheated
to 1,000 F (540 C) to prepare it for the turbine.

2.3 Steam Turbine operation & 2.4 Generator operations:


As all turbine and generator are connected through a common shaft so its
operations are described here both. There is a high pressure turbine at
one end, followed by an intermediate pressure turbine, two low pressure
turbines, and the generator. As steam moves through the system and
loses pressure and thermal energy it expands in volume, requiring
increasing diameter and longer blades at each succeeding stage to
extract the remaining energy. The entire rotating mass may be over 200
metric tons and 100 feet (30 m) long. It is so heavy that it must be kept
turning slowly even when shut down (at 3 rpm) so that the shaft will not
bow even slightly and become unbalanced. This is so important that it is
one of only five functions of blackout emergency power batteries on site.
Superheated steam from the boiler is delivered through 1416-inch (360
410 mm) diameter piping to the high pressure turbine where it falls in
pressure to 600 psi (4.1 MPa) and to 600 F (320 C) in temperature
through the stage. It exits via 2426-inch (610660 mm) diameter cold
reheat lines and passes back into the boiler where the steam is reheated
in special reheat pendant tubes back to 1,000 F (540 C). The hot reheat
steam is conducted to the intermediate pressure turbine where it falls in
both temperature and pressure and exits directly to the long-bladed low
pressure turbines and finally exits to the condenser.
The generator, 30 feet (9 m) long and 12 feet (3.7 m) in diameter,
contains a stationary stator and a spinning rotor, each containing miles of
heavy copper conductorno permanent magnets here. In operation it
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generates up to 10000 amperes at 22000 volts AC(210 MWe) as it spins at
either 3,000 rpm, synchronized to the power grid. The rotor spins in a
sealed chamber cooled with hydrogen gas, selected because it has the
highest known heat transfer coefficient of any gas and for its
low viscosity which reduces windage losses. This system requires special
handling during startup, with air in the chamber first displaced by carbon
dioxide before filling with hydrogen. This ensures that the
highly explosive hydrogenoxygen environment is not created.
2.5 Condenser operation & 2.6 CT operation:
The condenser condenses the steam from the exhaust of the turbine into
liquid to allow it to be pumped. If the condenser can be made cooler, the
pressure of the exhaust steam is reduced and efficiency of
the cycle increases.
The surface condenser is a shell and tube heat exchanger in which cooling
water is circulated through the tubes. The exhaust steam from the low
pressure turbine enters the shell where it is cooled and converted to
condensate (water) by flowing over the tubes as shown in the adjacent
diagram. Such condensers use steam ejectors or rotary motordriven exhausters for continuous removal of air and gases from the steam
side to maintain vacuum.
The process is similar to that of a radiator and fan. Exhaust heat from the
low pressure section of a steam turbine runs through the condensing
tubes, the tubes are usually finned and ambient air is pushed through the
fins with the help of a large fan. The steam condenses to water to be
reused in the water-steam cycle. Air-cooled condensers typically operate
at a higher temperature than water-cooled versions. While saving water,
the efficiency of the cycle is reduced (resulting in more carbon dioxide per
megawatt of electricity).
From the bottom of the condenser, powerful condensate pumps recycle
the condensed steam (water) back to the water/steam cycle.
2.7 Ash handling plant operation:
At the bottom of the furnace, there is a hopper for collection of bottom
ash. This hopper is always filled with water to quench the ash and clinkers
falling down from the furnace. Some arrangement is included to crush the
clinkers and for conveying the crushed clinkers and bottom ash to a
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storage site. Ash extractor is used to discharge ash from Municipal solid
wastefired boilers.
Fly ash is captured and removed from the flue gas by electrostatic
precipitators or fabric bag filters (or sometimes both) located at the outlet
of the furnace and before the induced draft fan. The fly ash is periodically
removed from the collection hoppers below the precipitators or bag filters.
Generally, the fly ash is pneumatically transported to storage silos for
subsequent transport by trucks or railroad cars.
2.8 Grid operation: The power grid frequency is 60 Hz across North
America and 50 Hz in Europe, Oceania, Asia (Korea and parts of Japan are
notable exceptions) and parts of Africa. The desired frequency affects the
design of large turbines, since they are highly optimized for one particular
speed.
The electricity flows to a distribution yard where transformers increase the
voltage for transmission to its destination.

3. BOILER:
3.1 Definition of Boiler: Boiler is a closed vessel in which
the under pressure is transformed into steam by the application of heat.
3.1.1 FUNCTION: The function of Boiler is to transfer the heat
to the water in the efficient manner .
3.1.2 WORKING: The chemical energy converted into the
heat energy by the combustion process is absorbed by the boiler.
3.1.3 QUALITY: A boiler must be designed to absorbed the
maximum amount of heat release in the process combustion.
3.2. TYPES OF BOILER:

There are mainly two types of boiler water

tube boiler and fire tube boiler.


In fire tube boiler, there are numbers of tubes through which hot gases are
passed and water surrounds these tubes. Water tube boiler is reverse of
the fire tube boiler. In water tube boiler the water is heated inside tubes
and hot gasses surround these tubes.
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3.3 BOILER SYSTEMS:
1. Water treatment system
2. Feed water system
3. Steam System
4. Blow down system
5. Fuel supply system
6. Air Supply system
7. Flue gas system
3.4 WORKING OF WATER TUBE BOILER IN TPS:
The working principle of water tube boiler is very interesting and
simple. Let us draw a very basic diagram of water tube boiler. It consists
of mainly two drums, one is upper drum called steam drum other is lower
drum called mud drum. These upper drum and lower drum are connected
with two tubes namely down-comer and riser tubes as shown in the
picture. Water in the lower drum and in the riser connected to it, is heated
and steam is produced in them which comes to the upper drums naturally.
In the upper drum the steam is separated from water naturally and stored
above the water surface. The colder water is fed from feed water inlet at
upper drum and as this water is heavier than the hotter water of lower
drum and that in the riser, the colder water push the hotter water
upwards through the riser. So there is one convectional flow of water in
the boiler system.
A diagram of Longlitudal water tube boiler:

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3.5. BOILER DRUM & FURNACE: The boiler enclosures are in two parts,
the furnace or radiant zone and the rear pass or convection zone. The four
sides of the furnace have membrane type water cooled walls. A division
wall is provided on the centre line of the furnace extending the full depth
expect for gaps between division wall tubes & front/rear walls and in the
centre.
The single drum at the bottom and three drums on the top were
connected through a network of tubes which were welded to the drums
above and the single drum below. The rational demand of steam in terms
of capacity, pressure and temperature resulted in bi drums and single
drum boilers.
The separated steam is drawn out from the top section of the drum and
distributed for process. Further heating of the saturated steam will make
superheated steam normally used to drive a steam turbine. Saturated
steam is drawn off the top of the drum and re-enters the furnace in
through a super heater. The steam and water mixture enters the steam
drum through riser tubes; drum internals consisting of demister separate
the water droplets from the steam producing dry steam. The saturated
water at the bottom of the steam drum flows down through the down
comer pipe, normally unheated, to headers and water drum. Its
accessories include a safety valve, water-level indicator and level
controller. Feed-water of boiler is also fed to the steam drum through a
feed pipe extending inside the drum, along the length of the steam drum.

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3.5 STEAM FLOW:


Steam flow circuit for boiler

3.7 ECONOMISER: Economizer is a heat exchanger which takes heat


from the flue gas, and increases the temperature of feed water coming
from feed water common header to about the saturation temperature
corresponding to the boiler pressure. Throwing away the flue gases of high
temperature into the atmosphere involves a great deal of energy losses.
By utilizing these gases in heating feed water, higher efficiency and better
economy can be achieved, and hence the heat exchanger is called
Economizer.
Structurally economizer is a collection of bent hollow tubular elements
through which feed water passes. Outside of the tubes are heated by
Exhaust flue gases. More no. of water tubes more will be the heat

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exchange surface. No. of tubes and tube cross section are pre-designed as
per required boiler parameters.
In the T-S curve above, the shadow portion illustrates the zone of
economiser. The heat absorbed by feed water is denoted by Qeco.

3.8 WATER TUBES : These are also essential for Feed Water and Steam
Circuit of Boiler Water tubes are bent or straight hollow tubes through
which steam water mixture circulates. There are two types of water tubes,
viz. down-comer and riser. This down comer, riser assembly is also known
as Evaporator (or boiler proper). In the evaporator actual state change
from water to steam occurs. In the T-S diagram beside, the zone of
evaporator is illustrated. Qeva is the heat absorbed by evaporator. It is
mainly the latent heat of vaporization of water.

Down-comers are the water tubes through which water comes down from
steam drum to mud drum (see fig.). No vapour bubble should flow along
with saturated water from the drum to the down comers. This will reduce
the density difference and the pressure head for natural circulation.
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Risers are the water tubes through which steam water two-phase mixture
at saturation temperature goes up from mud drum to steam drum. Risers
are usually close to furnaces, while the down-comers are away from the
furnaces.

3. CIRCULATION : In a natural circulation boiler the circulation is


achieved by the difference in density when the water in the boiler is
heated. In natural circulation steam boilers the circulation of water is
by convection currents, which are set up during the heating of water. In
most of the boilers there is a natural circulation of water the fundamental
principle of which is based on the principle of Thermo siphon.

3.8 SUPERHEATER : Super heater is another important part of Feed


Water and Steam Circuit of Boiler Super-Heater is an important element
of the feed water-steam circuit. It is basically a heat exchanger in which
heat is transferred to the aturated steam to increase its temperature. In
high pressure boilers more than 40% of the total heat is absorbed by the
super heaters. The T-S diagram beside illustrates the heat absorbed by
the super heater and is denoted by Qsh.

An increase in inlet steam temperature gives a steady improvement in


cycle efficiency. Hence, the function of super-heater is to raise the overall
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efficiency. In addition, it reduces the moisture content in the later stages
of the turbine and thus increases the turbine internal efficiency.However,
the increase in temperature is limited by the properties of the construction
materials of boilers and turbines. Usually the optimum temperature of
steam is maintained 450oC at the turbine inlet.

Types of superheater in thermal power plant:


1. Primary superheater
2. Platron superheater
3. Final superheater

350

Primary
superhete

Platron
superheat
er

450

Final
superheater
540

3.9 REHEATER: After expanding through the high pressure turbine the
exhaust steam is returned to the boiler at 360C and 42 bar pressure for
reheating before being used in the intermediate pressure turbine.

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AIR PREHEATER: They are simply heaters that heat the air before it
enters the combustor, thence result in the fuel consumption and
increasing the thermal efficiency.
The fuel savings are nearly directly proportional to the air temperature
rise in the pre-heater. Typical savings are 4% for a 2000F air temperature
rise and about 11% for a 5000F temperature rise in the pre-heater.
Air pre-heater are also a requirement for the operation of pulverized-coal
furnaces to dry that fuel.

DEARATOR: The lower portion of dearator acts a surge vessel for the
boiler fed pump . The working part of deaerator is the smallest vertical
section on top of the surge vessel.
This particular temp corresponds to the boiling point of water. Then it can
be said deacontrols pressure.

4. STEAM TURBINE:
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4.1 Definition of steam turbine: A steam turbine is a device
that extracts thermal energy from pressurized steam and uses it
to do mechanical work on a rotating output shaft.
4.2 Type of Steam flow:
1. Axial
2. radial
3. mixed
4. Tangential
5. Re-entry
4.2 TYPE OF STEAM TURBINE:
1. Impulse turbines
2. Reaction turbine
1. Impulse turbine: An impulse turbine has fixed nozzles that orient the
steam flow into high speed jets. These jets contain significant kinetic
energy, which is converted into shaft rotation by the bucket-like shaped
rotor blades, as the steam jet changes direction. A pressure drop occurs
across only the stationary blades, with a net increase in steam velocity
across the stage. As the steam flows through the nozzle its pressure falls
from inlet pressure to the exit pressure (atmospheric pressure, or more
usually, the condenser vacuum). Due to this high ratio of expansion of
steam, the steam leaves the nozzle with a very high velocity. The steam
leaving the moving blades has a large portion of the maximum velocity of
the steam when leaving the nozzle. The loss of energy due to this higher
exit velocity is commonly called the carry over velocity or leaving loss.

blade=

2 UVw
V 12

& stage=

U Vw
H

eff=blade* stage

Reaction Turbine: In the reaction turbine, the rotor blades themselves are
arranged to form convergent nozzles. This type of turbine makes use of
the reaction force produced as the steam accelerates through the nozzles
formed by the rotor. Steam is directed onto the rotor by the fixed vanes of
the stator. It leaves the stator as a jet that fills the entire circumference of
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the rotor. The steam then changes direction and increases its speed
relative to the speed of the blades. A pressure drop occurs across both the
stator and the rotor, with steam accelerating through the stator and
decelerating through the rotor, with no net change in steam velocity
across the stage but with a decrease in both pressure and temperature,
reflecting the work performed in the driving of the rotor.

4.3 CYLINDER ARRENGEMENT IN STEAM TURBINE:


1.
Tandem 3 cylinder turbine
2.
Tandem 4 cylinder turbine

Figure 1

Figure 2

Basically the second arrangement is quite useful for the TPS and
in KTPS also they used such a kind of arrangement for
generation.
4.4 TURBINE LOSSES:
1.ADMISSION LOSSES :i n practice the flow of steam through nozzle is
not isentropic, but accompanied with losses which decrease the kinetic
energy of steam coming out of the nozzle.

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2. Leakage losses : Steam leaves the boiler and reaches
the condenser after passing through the main valve, regulating valves,
nozzles, clearance spaces between nozzles and moving blades, diaphragm
and rotating shaft etc. Further there is large pressure difference between
inside of steam turbine and the ambient and also from one location to
another location across these devices.
4.6 STEAM TURBINE LAYOUT OF KTPS

4.7 STEAM TURBINE EQUIPMENT AND AUXILIARIES:

4.7.1 TURBINE ROTOR:


A multi stage turbine are manufactured with solid forged rotor are
precisely machined from solid alloy steel forgings. An integrity forged rotor
provides increased relatively particularly for high speed applications.

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The complete rotor assembly is dynamically balanced at operating speed
and over speed in a vacuum breaker to ensure safety in operation. High
balancing can also reduce residual stress and the effects of blade seating.

4.7.2 TURBINE CASING: the casing of turbine cylinders is of simple


constructions to minimize any distortion due to temperature changes.
They are constructed in two halves (top and bottom) along a horizontal
joint so that the cylinder is easily opened for inspection maintenance.

4.7.3 TURBINE BLADES: Turbine blades are of two basic types, blades and
nozzles. Blades move entirely due to the impact of steam on them and
their profiles do not converge. This results in a steam velocity drop and
essentially no pressure drop as steam moves through the blades. A
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turbine composed of blades alternating with fixed nozzles is called
an impulse turbine, Curtis turbine, Rateau turbine, or Brown-Curtis
turbine. Nozzles appear similar to blades, but their profiles converge near
the exit. This results in a steam pressure drop and velocity increase as
steam moves through the nozzles. Nozzles move due to both the impact
of steam on them and the reaction due to the high-velocity steam at the
exit. A turbine composed of moving nozzles alternating with fixed nozzles
is called a reaction turbine or Parsons turbine.

4.7.4 TURBINE COUPLING: With multi cylinder turbines it is necessary to


have some method of connecting individual cylinder rotors. It is also a
requirement to connect the turbines it is necessary to have some method
of connecting individual cylinders to connect the turbine to the alternator
rotor. to achieve these conditions we use a device known as a coupling.
These coupling must be capable of transmitting heavy loads and in some
turbines are required to accommodate for axial expansion and
contraction.
Flexible coupling

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Solid shaft coupling

4.7.5 TURBINE BEARINGS:


1. JOURNAL BEARING: The turbine rotor a supported by two journal
bearings. Both the no.1 and no.2 bearings are double tilting pad type.

TAPPERED LAND THURST BEARINGS: The thrust bearing is located on the


main shaft of the turbine independently mounted inside the standard the
thrust bearing absorbs the axial thrust.

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4.7.6 TURBINE SEALING SYSTEM: A Labyrinth seal is a type of mechanical
seal that provides a tortuous path to help prevent leakage. A Labyrinth
seal may be composed of many grooves that press tightly inside another
axle or inside a hole.
Labyrinth seal are utilized as end glad and also inter stage seals.
Stationary labyrinth seals are standard for all multistage turbines and
grooves are machined on the rotating part to improve sealing effect.

4.8 TURBINE SUPERVISARY INSTRUMENT AND STREAM CONTROL:


Turbine supervisory instrument (TSI) is a generic term used in power
generation industrys refers to instrumentation system that specially
perform measurement of critical control parameters on large steam
turbine generator trains.
The following are measured in supervisory system of turbine:
1. Vibration
2. Thrust bearing wear
3. Exhaust hood temp
4. Oil system pressure
5. Bearing and oil drain temp
6. Shell temp
7. Valve positions
8. Shell and rotor differential expansion
9. H2 temperature and pressure
10.
Turbine gland sealing pressure

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STEAM CONTROL:
MAIN STEAM STOP VALVE: The Main steam stop valve is located in the
main steam piping between the boiler and the outlet piping to turbine
casing the main stop valve has one inlet and two identical outlet pipe
connections.
The primary work function of main steam stop valve is to quickly shut off
the steam flow.

THE CONTROL VALVE : the control valve are arranged into an upper and
lower valve group with each mounted on common chest which is an
integral part of the upper and lower turbine outer shells .
CV admits steam from value chest of its group to individual nozzle box.

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THE INTERCEPT VALVE:

4.9 THE TURBINE GOVERNING COINTROL: The control of a turbine with


a governor is essential, as turbines need to be run up slowly to prevent
damage and some applications (such as the generation of alternating
current electricity) require precise speed control. Uncontrolled
acceleration of the turbine rotor can lead to an overs peed trip, which
causes the nozzle valves that control the flow of steam to the turbine to
close. If this fails then the turbine may continue accelerating until it
breaks apart, often catastrophically. Turbines are expensive to make,
requiring precision manufacture and special quality materials.
During normal operation in synchronization with the electricity network,
power plants are governed with a five percent droop speed control. This
means the full load speed is 100% and the no-load speed is 105%. This is
required for the stable operation of the network without hunting and dropouts of power plants. Normally the changes in speed are minor.
Adjustments in power output are made by slowly raising the droop curve
by increasing the spring pressure on a centrifugal governor. Generally this
is a basic system requirement for all power plants because the older and
newer plants have to be compatible in response to the instantaneous
changes in frequency without depending on outside communication.

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5. CONDENSER:
5.1 Definition of condenser:
Steam condenser is a device in which
the exhaust steam from steam turbine is condensed by means of
cooling water. The main purpose of a steam condenser in turbine is to
maintain a low back pressure on the exhaust side of the steam turbine.
After releasing from nozzles, the steam has to expand to a great extent
for converting available energy into it to usable mechanical work. So, if
the steam after doing its, work, does not get condensed, it will not give
required space to other steam behind it, to expand to its required
volume.

Condensation of steam in a closed system, creates an empty place by


reduction of volume of the low pressure steam. It is found that, 1 Kg of
dry steam at 1.033 kg / cm2 absolute pressure has a volume of 1.673
m3 when it is condensed into water at 100C in a steam condenser, its
volume becomes 0.001044 m3. The volume of steam would be thus
1/1644 parts of the space inside the vessel, and the pressure would fall
to 0.2 kg / cm2 absolute pressure. This means, pressure in the exhaust
of the turbine falls to 0.2 kg / cm2 from 1.033 kg / cm2.
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ELEMENTS OF STEAM CONDENSER :
1) Condenser chamber where steam gets condensed.
2) Cooling water supply which provides cold water to condense
steam by heat exchanging.
3) Wet Air pumps They collect condensed steam, the air and uncondensed water vapour and gases from condenser.
4) Hot well- in which the condensed steam is collected and from it
steam boiler feed water may be taken if required.

5.2 WORKING OF A CONDENSER:


The main heat transfer mechanism in a surface condenser is the
condensing of saturated steam on the outside of saturated steam on the
outside on the tubes and the heating of the circulating water inside the
tubes.
Thus for a given circulating water flows rate ,the water inlet temperature
to the condenser determines the operating pressure of the condenser as
this temperature is decreased and pressure is also decreased. As
described above the decreased in the pressure will increase plant output
and the efficiency of power plant.
Some non-condensable gases must be vented out from the condenser.

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5.3 FUNCTION OF CONDENSER IN POWER CYCLE:


1. Function of condenser is to create a vacuum by condensing steam
2. Removing dissolved non condensable gases from the condensate
steam
3. Conserving the condensate for re use as the feed water for supply
4. Providing a leak tight barrier between the high grade condensate
contained within
5. Providing a leak-tight barrier against ingress preventing excess back
pressure
turbine.

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5.4 CONENSER ASSOCIATIVE EQUIPMENT AND THEIR FUNCTION :


1. CEP- Condensate from condenser hot well is pumped through main
ejectors, Gland cooler 1 ,LP heater no1, Gland cooler no 2,LP heaters 2,3
and 4 up to DE aerator by 350% capcity condensate extraction pumps .
Normally two pumps will be in operation for generating 210 MW .
It is also used by different purpose:
1. Sealing of valves with gland seal.
2. For LP bypass temp control
3. For cooling down the steam dumped in steam throw off from LP
Bypass valves.
2. L.P. heater no-4- extraction no 4 is extraction from IP turbine and is
connected to
LP heater no 4 with normal parameters of 6.95
ata/c .It is provided with hydraulically operated NRV ES-9 near extraction
point and motorized gate valve ES-12 near heater connection.
Leak off steam from IP turbine front and HP turbine rear is led into
extraction no-4 steam through isolating valve AS-40 & AS-39 .
3.L.P Heater no-3- Extraction no-3 is third extraction from IP Turbine and
is connected to LP heater no-3 with normal parameters 2.97 ata/263c .
4. L.P Heater no-2 --- extraction no-2 is the fourth extaction from LP
turbine and is connected to LP heater no-2 with normal parameters
1372/183 C
5. L.P Heater no-1 consists with general parameter .

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6. GC- 1 (gland cooler) gland cooler no-2 draws leak off steam from
third pocket from air side of HP and IP turbine glands. The steam side of
the gland cooler NO-2 is also connected to main condenser .Gland cooler
no-2 together with the 3rd pocket of the turbine glands is thus always
maintained at main condenser vacuum .
7. GC-2 --- Gland cooler number 1 draws off steam from the 1st pocket
from air side of HP,IP,LP turbine and air side leak off steam from ESV,
HPCV ,IV and IPCV. It employs a small ejector for which the working
medium is steam of low parameters which can be taken either from
Dearator or TAS source.

5.6 A BRIEF IDEA OF CW SYSTEM: At full load operation of the unit ,about
480 T/hr of steam is exhausted into two surface condenser . About
27000T/hr of cooling water is required for condensing this exhaust steam .
The cooling water is required for condensing this exhaust steam . the
cooling water is supplied by three nos of 33% capacity vertical mixed flow
pump of 9000T/hr. capacity each .
18 nos of circulating pumps of all six units are located in the common C.W
pump House and take suction from the common C.W basin . Each C.W
pump is provided with separate suction from the common C.W basin .
Each c.w pump is provided with separate suction bay with isolating gate .
All the pump discharge into the common 2.2 m dia C.W header supplying
to to the twin condenser. the normal inlet and outlet of the condenser. The
normal inlet and outlet of the condenser are through the bottom and top
respectively. In inlet and out let there are motor operated butterfly valves.
The hot water outlet from the condenser, discharging into 2.2 m dia . Pipe
taken to cooling water tower provided for each unit of 32000 T/h
capacities. The cooling tower is induced draft, cross flow type consisting of
8 nos cells. The water enter the distributing header at tower top ,flows
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into distributing basin which forms the roof of the tower , through
individual branch pipes to each cell with valve. The water flows down to
wood fill through the nozzles provided on the basin. The dripping in
droplets through the fill collects at bottom basin. The air flowing across
the water steam around the wood fill is sucked by the fan at the top and
discharging into atmosphere. The cooled water collected at bottom basin
flows back to C.W basin through the individual tunnel of each unit to
common tunnel.
5.7 ACW SYSTEM: Two numbers of pumps are used in ACW system for
cooling purpose .each pup capacity of 2500

m3 /hr. .It also goes through

the heat exchanger and the water used here is basically DM water.
6. COAL HANDLING PLANT :
6.1 DEFINATION OF COAL HANDLING PLANT: CHP (C- Coal, H- Handling, PPlant)
This properly handles the coal from its receipt to transferring it to bunkers.
OBJECTIVE OF COAL HANDLING PLANT:
1. To supply the quanta of processed coal to bunkers of Coal mills for
Boiler operation.
2. To stack the coal to coal yard.
6.2 GENERAL LAYOUT OF CHP:

6.3 SECTIONS OF CHP:


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1. Management of coal
2. Transportation of the Coal
3. Handling of coal
1. Management of coal:
1. Central government
2. CIL
3. WCL
4. Railway
2. TRANSPORTION OF COAL:

1.roadway
2.railway
3.ropeway
WAGON TIPPLERS: wagon tipplers are basically two types described

below6.5 OPERATION CYCLE FOR COAL UNLODING : Here is a view of coal


unloading of the KTPS from mecheda and kolaghat.

Drawing of KTPS yard are below :

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The basic operation cycle of coal unloading are described below.

R a k
e
s h u
n ti
n g
fo r
p la
ce
m e A i
n t
r
a t
R e
T /H
le
,
W T a s

M E
C H
E D
A /
K O
L A
G H
AT
S ta
t io
n

S e

L o a
cu
d
r
it
P la
ce
y
m e G a
n t
te
b y
R a il
w a
y
A t
K T P
S
Ya r
d

K T P S
E n g in e
a tta c h m e
n t

6.5 LAYOUT OF KTPS COAL HANDLING PLANT:

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6.6 OPERATIONS CYCLE CHP:


1. Bunkering cycle
2. Stacking cycle of CHP
3. Reclaiming cycle of CHP
1. Bunkering cycle of KTPS: BOBR WAGONS are placed on the track
hoppers consisting of 52 nos hoppers of 80 tons capacity. The in-motion
weighbridge situated at pre track hopper, weigh and record the weights of
Bobr wagons. When the gates of are opened by introducing compressed
air in actual cylinder, coal will in the hopper. Hoppers are covered by
gratings of (300300) mm size .oversized of coal are broken manually
into smaller pieces. This coal is then fed to conveyors 2A/1 & 2B/1 by
plough feeders and subsequently conveyed to the surge hoppers. From
Surge hoppers. From surge hoppers coal is taken to the vibrating feeders
through Rod gates and rack pinion gates. Feeding of coal is cby vibrating
feeders (VFD-49, 50, 51, 52) from where it is fed to conveyors 2A, 2B,
2C&2D respectively as per necessity. In recent modifications it has been
possible to feed coal parallel through 2A/1 and 2B/1 and convey it through
two separate routes both originating from track hoppers .
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Now this conveyors belts will fed 3A,3B,3C &3D and the same process will
continue to 4A,4B,4C,4D and the process is goes to stacker yard of the
cycle.
2. STACKING PROCESS: 6A, 6B,6C are yard conveyors with a stacker cum
reclaimer on each of them .while feeding coal to the bunkers these stacker
cum reclaimer remain in direct mode thereby the SRs,6A feeds coal to
conv 7A/7B/7C/7F by suitable positioning the flap gates FG-39,FG-11,and
FG-38.similarly 6B,6C feeds coal to remaining chains .

3. RECLAIMING PROCESS: the crushed coal from the stock pile can also be
reclaimed through the hoppers over the conveyor -7A,7B,7C and 7D .
these hoppers are equipped with rack and pinion gates. Coal from yard -2
is fed in the hoppers of vibrators No-17, 18,19,20,21,22,23,24 by dozer. In
the same way dozer feeding is done from yard no-3.
A basic cycle for reclaiming process:

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6.7 EQUIPMENTS USED IN CHP OPERATIONS:
1. Pull chord switch: A series such switches are arranged in series at
a 1m distance on the side of conveyor belt.
2. Vibrating feeder: The coal stored in a huge hub is collected on the
belt through vibrations created by the vibrating feeders.
3. Flap Gates: These are used to channelize the route of coal
through another in case the former is broken or unhealthy. The flap gates
open let the coal pass and it closed stop movement.
4. Magnetic separator: These are used to separate the ferrous
impurities from the coal.
I.
II.

INMS-in line magnetic separator


CBMS-cross belt magnetic separator

.
5.Metal detector: This will detect the presence of any ferrous and
non-ferrous metal in the coal and sends a singnal to a relay which closes
to seize the movement of belt until the metal is removed . It basically
consists of a transmitter and receiver.
6. Belt weightier: it is used to keep account of the tension on the belt
carryimg coal and is moves accordingly to release tension on the belt.
7. Reclaim Hoppers: Reclamation is a process of taking coal from the
dead storage for preparation or fur their feeding to reclaiming hoppers.
This is accomplished by the belt conveyors.
8. Conveyor Belts :

9.IDLERS : Consists of 3 rollers .rrollers are fitted with bearings /Life


sealed bearings .
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Fitting arrangement:
1. Fixed
2. detachable

10.Pulleys : These are heavy cast iron ,driving pulleys are faced with ferodo or
similer frictional materials .

6.9 COAL ANALYSIS :


I.
II.

Proximate analysis
Ultimate analysis

7.ASH HANDLING PLANT:


7.1 Definition of ash handling plant : The ash handling system
handles the ash by bottom ash handling system, coarse ash handling
system, fly ash handling system, ash disposal system up to the ash
disposal area and water recovery system from ash pond and Bottom
ash overflow.
7.2 General diagram of ash handling plant:

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7.3 Requirement of ash handling plant:


I.
II.

In Thermal Power Plants coal is generally used as fuel and


hence the ash is produced as the byproduct of Combustion.
Ash generated in power plant is about 30-40% of total coal
consumption and hence the system is required to handle Ash
for its proper utilization or disposal.

7.4 Parts of ash handling plant:


1. Bottom ash handling plant: Bottom ash resulting from the
combustion of coal in the boiler falls into the over ground, refractory lined,
water impounded, maintained level, double V-Section type/ W type steelfabricated bottom ash hopper having a hold up volume to store bottom
ash and economizer ash of maximum allowable condition with the rate
specified. The slurry formed is transported to slurry sump through pipes.

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2. Coarse ash handling plant: Ash generated in Economizer hoppers


is evacuated continuously through flushing boxes.
Continuous generated Economizer slurry is fed by gravity into
respective bottom ash hopper pipes with necessary slope.
3. Air pre heater ash handling plant: Ash generated from APH
hoppers is evacuated once in a shift by vacuum conveying system
connected with the ESP hopper vacuum conveying system.

4. Fly ash handling plant: Fly ash is considered to be collected in ESP


Hoppers.
Fly ash from electrostatic precipitators or fabric bag filters (or
sometimes both), located at the outlet of the furnace and before the
induced draft fan, is extracted by Vacuum Pumps.

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7.5 Ash slurry disposal system: Bottom Ash slurry, Fly ash slurry and
the Coarse Ash slurry shall be pumped from the common ash slurry
sump up to the dyke area which is located at a distance from Slurry
pump house.

8. DM WATER SYSTEM AND CHEMICAL PLANT IN DM PLANT AND


CHEMICAL LABORATORY:
8.1 Sources of water in DM plant: In Kolaghat Thermal power station
water are supplied in DM Plant1. Rup Narayan River
2. Underground water
8.2 Impurities in water: Insoluble impurities are very largely metal
oxides derived from corrosion of the plant itself, particularly the
materials of construction of the condenser and feed systems. Such
corrosion is minimised by maintaining the feed water at an alkaline pH
and by removing dissolved oxygen down to very low concentrations.
Soluble impurities in feed water most frequently arise from in leakage
of cooling water from condensers and other coolers, but can also
results from poor quality of make-up water.
8.3 Importance of water treatment:
I.

To prevent scaling on stream generating surface


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II.
III.
IV.

To give adequate protection to various metallic surface from


corrosion attack
To prevent turbine and its aux.
To achieve heat utilization

8.4 Stages of water treatment:


I.
II.

Pre-treatment plant
Demineralization plant

8.4.1 Pre-treatment plant : A flow chart can be presented regarding this


pre treatment plant of thermal power station.
1. Coagulation
2. Flocculation
3. Sedimentation
4. Filtration
5. Disinfection
1.Coagulation: It is the process of destabilization by charge neutralization .
Once neutralized, particles no longer repel each other and can be
brought together . Coagulation is necessary for the removal of colloidal
sized suspended matter.

2.Flocculation: Flocculation is the process of bringing together the


destabilized or
Coagulated particles to form a larger agglomeration, or floc.
3.Sedimentation : Sedimentation refers to the physical removal of
suspension, or settling, that occurs once the particles has been
coagulated and flocculated.
4. Filterration: The process of passing water through a filter to remove
particles. In water treatment, the filter material is typically sand,
sometimes with a layer of anthracite (coal) above

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5. Disinfection: The process of killing disease-causing microorganisms.
Commonly Chlorine is used as a disinfectant in pre-treatment of water.

8.4.2 DEMINARALIZATION PLANT:


DEMINERALIZATION BY ION- EXCHANGE PROCESS-----Ion exchange is the reversible interchange of ions between a solid (ion
exchange material) and a liquid in which there is no permanent change in
the structure of the solid. Ion exchange is used in water treatment and
also provides a method of separation for many processes involving other
liquids. It has special utility in chemical synthesis, medical research, food
processing, mining, agriculture, and a variety of other areas. The utility of
ion exchange rests with the ability to use and reuse the ion exchange
material.

ACTIVATED CARBON FILTER (ACF): Acts on principle of adsorption which is a


surface active phenomenon .It removes residual turbidity (<2 NTU) of water
to its 1/10 level.It removes organic molecules to control color and odor.

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WEAK ACID CATION (WAC): Weak acid cation exchange resins derive their

exchange activity from a carboxylic group (-COOH). When operated in the


hydrogen form, WAC resins remove cations that are associated with
alkalinity, producing carbonic acid.

STRONG ACID CATION (SAC): SAC resins can neutralize strong bases and
convert neutral salts into their corresponding acids. SAC resins derive their
functionality from sulfonic acid groups (HSO3). When used in
demineralization, SAC resins remove nearly all raw water cations,
replacing them with hydrogen ions.
DEGASIFIER: In water demineralization, a degasifier, or degasser, is often
used to remove dissolved carbon dioxide after cation exchange. The most
common degassers are of the so-called forced draft or atmospheric type.

Aft
er cation exchange, the bicarbonate and carbonate (if any) ions are
converted to carbonic acid, or carbon dioxide. CO2 is soluble in water, but
it tends to escape into the air, much as it does in a glass of Cold drink
when you stir it. Using a degasser to remove CO2 reduces the ionic load on
the strong base anion resin, and the consumption of caustic soda is thus
lower.

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9. GENERATOR: Generator or the alternator as it usally called is the
electrical end of a turbo generator set. It is a cylindrical pole(Two pole for
a 50Hz suppy) synchronous generator. It is generally known as the piece
of equipment that actually converts the mechanical energy of turbine into
generation of electricity is based on the principle of electromagnetic
induction.
9.1 Development of large generators: In the development of large
generators the cost and labour involved in manufacture and erection, is a
basic consideration. Coupled very closely with this consideration is the
restriction in size and weight imposed by transport limitations.
The designer of large turbo generator must be conscious of the problem of
the transporting heavy loads. Although the maximum transportable
weight allowed on rail /roads continue to increase with the importance in
rail tracks /roads themselves, the limitations will still have to be observed.
A Generator consists of the following main components and associative
system.
9.2 Basic components of a generator :
I.
II.
III.
IV.
V.
VI.

Stator
Rotor
Excitation system
Cooling system
Sealing system
Protections

Stator: The stator is the outer stationary part of the machine, which
consists of. The outer cylindrical frame called yoke, which is made either
of welded sheets steel,
Cast iron. The magnetic path, which comprises a set of slotted steel
laminations called stator core pressed into the cylindrical space inside the
outer frame. The magnetic path is l laminated to reduce eddy currents,
reducing losses and heating. CRGO laminations of0.5 mm thickness are
used to reduce the iron losses. A set of insulated electrical windings are
placed inside the slots of the laminated stator.
The cross-sectional area of these windings must be large enough for the
power rating of the machine. For a 3-phase generator, 3 sets of windings
are required, one for each phase connected in star. Fig. 1 shows one stator
lamination of a synchronous generator. In case of generators where the
diameter is too large stator lamination cannot be punched in on circular
piece. In such cases the laminations are punched in segments. A number
of segments are assembled together to form one circular laminations. All
the laminations are insulated from each other by a thin layer of varnish.

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Stator windings and insulation:

ROTOR: In case of turbo alternator the rotors are manufactured form solid
steel forging. The rotor is slotted to accommodate the field winding.
Normally two third of the rotor periphery is slotted to accommodate the
winding and the remaining one third unspotted portion acts as the pole.
Rectangular slots with tapering teeth are milled in the rotor. Generally
rectangular aluminium or copper strips are employed
For filed windings. The field windings and the overhangs of the field
windings are secured in place by steel retaining rings to protect against
high centrifugal forces. Hard composition insulation materials are used in
the slots which can with stand high forces, stresses and temperatures.
Perfect balancing of the rotor is done for such type of rotors. Damper
windings are provided in the pole faces of salient pole alternators. Damper
windings are nothing but the copper or aluminium bars housed in the slots
of the pole faces. The ends of the damper bars are short circuited at the
ends by short circuiting rings similar to end rings as in the case of squirrel
cage rotors. These damper windings are serving the function of providing
mechanical balance; provide damping effect, reduce the effect of over
voltages and damp out hunting in case of alternators. In case of
synchronous motors they act as rotor bars and help in self-starting of the
motor.
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Rotor windings and retaining rings: The rotor carries the field windings.
Silver bearing copper (containing 0.03) is used for the windings with mica
as the insulation between conductors. A mechanically Strong insulator
Such As micanite, is used for lining the slots. Later designs of winding
flange rotor incorporate combinations of hollow conductors with slots of
holes arranged to provide for circulation of the cooling gas through the
actual conductors. When rotating at high speed, centrifugal force tries to
lift the winding out of the slots are contained by duralumin wages.
Rotor Balancing: The final rotor is an end product of several machining
operations, however due to inaccuracies in the machining operations,
certain unbalance is likely to be introduced in the rotor. It is therefore,
necessary that when completed ,the rotor must be tasted for mechanical
balance. Which means that a check is made to see if it will run up to
normal speed without vibrations. If the residual unbalance is of larger
balance weights. Arrangements are therefore, made in all designs to fix
adjustable balance weights at each of the rotor.
Slip ring and Brush gear assembly: The slip ring assembly is made of alloy
steel and insulating material. It must safety withstand the stresses due to
centrifugal forces .Both the rings are mounted on a single common steel
bush,. Which has an insulating jacket premoduled on it.The complete bush
with slip rings, is shrunk on the rotor shaft? The slip rings are provided
with inclined holes for slip rings, is shrunk on the rotor shaft. The slip rings
are provided with inclined holes for self-ventilations
Brush gear is provided on the extended part of the bearing pedestal pond
the excitation side. Brush holders are fixed on brass ring, made in such a
way as to provide staggering of the brushes along with slip ring.
Generator Cooling System :
I.

Hydrogen Cooling :
Minimize drag - windage
Maximize generator output
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Minimize electrical, mechanical and corrosion problems
Better heat transfer
Increase breakdown voltage
II.

Generator sealing system:


Sealings are employed to prevent leakage of hydrogen from the
stator at the point of rotor exit.
The seal oil is a portion of the lube oil, diverted from the lube oil
system. It is then fed to a separate system of its own with pump,
motor, hydrogen detraining or vacuum degassing equipment, and
controls to regulate the pressure and flow.
A continuous film between the rotor collar and seal liner is maintained
by the means of oil at a pressure, which is about O.5 atm above the
casing of hydrogen gas pressure.
The thrust pad provides a positive maintenance of the oil film
thickness.

III.

Generator Seal Oil System:


System functions:

Supplying the generator shaft with seal oil with hydrogen.


Permanent monitoring and differential pressure regulation of hydrogen
and oil,
Oil seal maintenance
air and hydrogen separation,
oil filtration,
temperature regulation,
Generator Excitation:
The process of generating a magnetic field by means of an electric
current is called excitation.
It provides power to the field windings
thus produce field for rotor.
Brush type exciter / Static excitation: Rotor Field Winding is connected
to Slip ring mounted on Rotor.
Excitation is provided by current transfer by contact through Carbon
Brushes, Slip ring and field lead.

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Brush less exciter:

Generator Protection:
Under Electrical Protection a generator is subjected to electrical traces
imposed on the insulation of the machine, mechanical forces acting on the
various parts of the machine, and temperature rises. These are the main
factors which make protection necessary for the generator or alternator.
Even when properly used, a machine in its perfect running condition does
not only maintain its specified rated performance for many years, but it
does also repeatedly withstand certain excess of over load. Hence,
preventive measures must be taken against overloads and abnormal
conditions of the machine so that it can serve safely. Despite of sound,
efficient design, construction, operation, and preventive means of
protection, the risk of that fault cannot be completely eliminated from any
machine. The devices used in generator protection, ensure the fault,
made dead as quickly as possible. An electrical generator can be
subjected to either internal fault or external fault or both. The generators
are normally connected to an electrical power system, hence any fault
occurred in the power system should also be cleared from the generator
as soon as possible otherwise it may create permanent damage in the
generator. The number and variety of faults occur in generator, are huge.
That is why generator or alternator is protected with several protective
schemes. The generator protection is of both discriminative and nondiscriminative type. Great care is to be taken in coordinating the systems
used and the settings adopted, so that the sensitive, selective and
discriminative generator protection scheme is achieved.

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Protection against Insulation Failure:
Stator Earth Fault Protection
Rotor Earth Fault Protection
Protection against Stator Overheating
Low Vacuum Protection
Protection against Lubrication Oil Failure
Protection against Loss of Boiler Firing
Protection against Prime Mover Failure
Over Speed Protection
Protection against Rotor Distortion
Protection against Vibration

9.RELAY AND SWITCHGEAR AND CIRCUIT BREAKER:

RELAY: A relay is automatic device which senses an abnormal condition of


electrical circuit and closes its contacts. These contacts in turns close and
complete the circuit breaker trip coil circuit hence make the circuit breaker
tripped for disconnecting the faulty portion of the electrical circuit from
rest of the healthy circuit.

Pickup level of actuating signal: The value of actuating quantity (voltage or


current) which is on threshold above which the relay initiates to be operated.
If the value of actuating quantity is increased, the electromagnetic effect of the
relay coil is increased and above a certain level of actuating quantity the moving
mechanism of the relay just starts to move.
Reset level: The value of current or voltage below which a relay opens its contacts
and comes in original position.

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Operating time of relay -Just after exceeding pickup level of actuating quantity
the moving mechanism (for example rotating disc) of relay starts moving and it
ultimately close the relay contacts at the end of its journey. The time which elapses
between the instant when actuating quantity exceeds the pickup value to the instant
when the relay contacts close.
Reset time of relay The time which elapses between the instant when the
actuating quantity becomes less than the reset value to the instant when the relay
contacts returns to its normal position.
Reach of relay A distance relay operates whenever the distance seen by the relay
is less than the pre-specified impedance. The actuating impedance in the relay is
the function of distance in a distance protection relay. This impedance or
corresponding distance is called reach of the relay.
Power system protection relays can be categorized into different types of relays.

Based on Characteristic the protection relay can be categorized as1.

Definite time relays

2.

Inverse time relays with definite minimum time(IDMT)

3.

Instantaneous relays.

Based on of logic the protection relay can be categorized as1.

Differential.

2.

Unbalance.

3.

Neutral displacement.

4.

Directional.

5.

Restricted earth fault.

6.

Over fluxing.

7.

Distance schemes.

8.

Bus bar protection.

9.

Reverse power relays.

Thermal: OT trip (Oil Temperature Trip) (b) WT trip (Winding Temperature


Trip) (C) Bearing temp trip etc.
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Float type: Buchholz, Water level Controls

SWITCHGEAR: A switchgear or electrical switchgear is a generic term


which includes all the switching devices associated with mainly power
system protection. It also includes all devices associated with control,
metering and regulating of electrical power system. Assembly of such
devices in a logical manner forms a switchgear. This is very basic
definition of switchgear.
Switchgear has to perform the function of carrying, making and breaking
the normal load current like a switch and it has to perform the function of
clearing the fault in addition to that it also has provision of metering and
regulating the various parameters of electrical power system. Thus the
switchgear

includes

circuit

breaker,

current

transformer,

voltage

transformer, protection relay, measuring instrument, electrical switch,


electrical fuse, miniature circuit breaker, lightening arrestor or surge
arrestor, electrical isolator and other associated equipment.

CIRCUIT BREAKER: Electrical circuit breaker is a switching device which


can be operated manually as well as automatically for controlling and
protection of electrical power system respectively. As the modern power
system deals with huge currents, the spacial attention should be given
during designing of circuit breaker to safe interruption of arc produced

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during the operation of circuit breaker. This was the basic definition of
circuit breaker.
Working Principle of Circuit Breaker: The circuit breaker mainly consists of
fixed contacts and moving contacts. In normal "on" condition of circuit
breaker, these two contacts are physically connected to each other due to
applied mechanical pressure on the moving contacts. There is an
arrangement stored potential energy in the operating mechanism of
circuit breaker which is realized if switching signal given to the breaker.
The potential energy can be stored in the circuit breaker by different ways
like by deforming metal spring, by compressed air, or by hydraulic
pressure. But whatever the source of potential energy, it must be released
during operation. Release of potential energy makes sliding of the moving
contact at extremely fast manner. All circuit breaker have operating coils
(tripping coils and close coil), whenever these coils are energized by
switching pulse, the plunger inside them displaced. This operating coil
plunger is typically attached to the operating mechanism of circuit
breaker, as a result the mechanically stored potential energy in the
breaker mechanism is released in forms of kinetic energy, which makes
the moving contact to move as these moving contacts mechanically
attached

through

gear

lever

arrangement

with

the

operating

mechanism. After a cycle of operation of circuit breaker the total stored


energy is released and hence the potential energy again stored in the
operating mechanism of circuit breaker by means of spring charging
motor or air compressor or by any other means. Till now we have
discussed about mechanical working principle of circuit breaker. But there
are electrical characteristics of a circuit breaker which also should be
consider in this discussion of operation of circuit breaker.
According to their arc quenching media the circuit breaker can be divided
as1.

Oil circuit breaker.

2.

Air circuit breaker.

3.

SF6 circuit breaker.

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4.

Vacuum circuit breaker.

According to their services the circuit breaker can be divided as1.

Outdoor circuit breaker

2.

Indoor breaker.

According to the operating mechanism of circuit breaker they can be


divided as1.

Spring operated circuit breaker.

2.

Pneumatic circuit breaker.

3.

Hydraulic circuit breaker.

10.ELECTRICAL CONTROL AND SWITCHYARD:


10.1 Control Panel: Control panel is a cabinet which contains electrical
components to control the motors and equipments.

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CABLES: Cables are used for the interconnection. Two types of cables are
used. Power cable and control cable.
1. Power cables (which is used to connect the motor to panel component
and panel to main supply)
2. Control cables (which is used to connect the control circuits)

BUS BAR: Incoming supply is connected to bus bar and distributed from
bus bar. It is normally made by Aluminium.
MCB (Miniature Circuit Breakers): MCB is a protecting device. It is used
before the feeder. This should be selected according to the capacity of the
feeder.

MCCB (Mould Case Circuit Breaker): In most of the cases the MCCB used
as an incomer for higher capacity feeders for better protection.
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ELCB (Earth Leakage Circuit Breaker): The ELCB is also known as RCCB.
The device used for the protection against the earth leakage current and
residual current. It should be fixed before the incomer.
INCOMER: The basic supply will connected to this incomer. It also called as
SFU(Switch Fuse Unit). It contains one handle with fuse unit. Once it is
turned ON the supply will pass to the next stage through fuse if any major
fault occurs in side panel board, it will trip and it isolate supply.

SELECTOR SWITCH: Selector is switch is used for ON/OFF purpose and for
selecting the mode of operation like auto/manual.

Starters: are used for starting the motors safely. Mainly two types of
starters are there. DOL starters and Start to delta. Dol starter is enough
for the motors with power less than 10 hp.
OVER LOAD RELAY: Over load relay is for the protection of motor from the
over load. It senses the load current and trips if it exceeds the limit.
Current limit has to be set manually. It should be 80% of the full load
current.

TIMER: Operation of timer is similar to relay. But a delay is there for


actuation. We can set the time delay manually according to our
requirement. It is very much essential for start to delta conversion.

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CONTACTOR: Contactor is an essential component in the control panel. It
actuates when the signal from the controller (PLC, Relay logic) comes. It is
similar to relay. It is costlier than relay. It is used for a higher load.
10.2 SINGLE LINE DIAGRAM OF KTPP SWITCHYARD:

COMPONENTS IN SWITCHYARD:
Lightening arresters
Current Transformer (C.T.)
Potential Transformer (P.T.)
Line isolator with Earthing switch
SF6 Circuit breaker with starting
resistance
Bus isolator
3 phase reactor
Wave trap
Power transformers
Cables trench & tray
Firefighting facility

Lightening arresters: The lightening arresters (L.A.) are used to ground


the high voltage impulse falling on line during lightening.L.A. of all the
lines connected to a bus are connected in parallel in order to ensure
the proper grounding of surge as well as to increase its life.The L.A.
core is made up of Zinc Oxide (ZnO2). It acts as a non-linear resistance

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i.e. it offers a very high resistance during normal conditions and offers
low resistance to the surge voltages.

Current Transformer (C.T.): Used to measure phase current.


1. Potential Transformers (P.T.) : Used to measure phase to neutral
voltage.
In this yard at some places CVT (Capacitive Voltage Transformers) are
used which does function of PT as well as assisting the Wave Trap.

Centre Break Isolator

Double Break Isolator

Pantograph type

bus isolators

The line isolators are used to isolate the line (after the operation of
opening C.B.) under maintenance from the healthy system which
otherwise may get resulted in L-G fault.
The bus isolators are used to isolate the bus under maintenance.

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In this substation normally line isolators were centre break type
isolators while the bus isolators were either double break type OR
pantograph type isolators.
The disc type structure at the tips of centre break type isolator is to
reduce the corona loss while they are open.
Circuit breakers: In this substation almost all the circuit breakers are
SF6 type circuit breakers.

Power transformer: two type of power transformers:


1) 400 kV 220 kV and
2) 220 kV 132 kV
The cooling system employed is forced air forced oil.

Cables trench & tray: The cables that collect the communication signals
from instrument transformers, circuit breakers, isolators, wave traps
etc. are made to run in cable trench towards the control room.

FIIRE FIGHTING FACILITY: As oil is used as coolant and body insulator,


there are possibilities of fire in case of short circuits.
Fire fighting facility available in two ways in this yard.

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