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GITAM UNIVERSITY

GITAM INSTITUTE OF TECHNOLOGY DEPARTMENT OF ELECTRONICS & INSTRUMENTATION ENGINEERING INDUSTRIAL TRAINING REPORT NTPC DADRI POWER PLANT STUDENT : AKASH RANJAN 1210608102 TRAINING PLACE NAME : NTPC DADRI (NATION CAPITAL POWER STATION )

ADDRESS : NTPC-Dadri,Vidyut Nagar-201008,Dist. Gautambudhnagar,UP TRAINING DATE: Starting 01/06/2011 Completion: 30/06/2011 PHONE NO: WEB ADDRESS: 2671284 www.ntpc.co.in

Name & Designation External Supervisor

Name & Designation Internal Supervisor

Name & Designation Coordinator, Industrial Training

STUDENT DECLARATION

I hereby declare that this industrial training report titled NTPC DADRI POWER PLANT in NTPC is executed as per the course requirement for the under graduate program in engineering. It have not been submitted by me or any other person to any other university or institution for degree or diploma. Its my own work.

Place: Date:

AKASH RANJAN

Department of Electronics & Instrumentation Engineering GITAM University Visakhapatnam - 530045

CERTIFICATE

This is to certify that Mr.

AKASH RANJAN

of B. Tech

(Electronics & Instrumentation Engineering)

Roll No. 1210608102

has completed/ partially completed/ not completed his Industrial Training during the acedemic year 2010-2011 as the partial fulfilment of the B.tech course.

Signature Name & Designation Internal Supervisor

Signature Name & Designation Coordinator, Industrial Training

ACKNOWLEDGEMENT

With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here. I express gratitude to the Program Manager and other faculty members of Electronics & Instrumentation Engineering og GITAM Institute of Technology for providing this opportunity to undergo industrial training at National Thermal Power Corporation, Dadri, New Delhi. I do extend my heartfelt thanks to Ms. C. S. M. Burlawar for providing me this opportunity to be a part of this esteemed organization. I am extremely grateful to Mrs.Rashmi Mathur, Senior Engineer, C & I Department at NTPC Dadri Gas Plant, Dadri for his guidance during whole training. I am extremely grateful to all the technical staff of NTPC DADRI GAS PLANT for their co-operation and guidance that helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me. Finally, I am indebted to all whosoever have contributed in this report work and friendly stay at Nationsl Capital Power Station, Dadri, UP.

AKASH RANJAN 1210608102

Contents 1. Introduction 2. About NTPC 2.1Overview of NTPC 2.2Dadri Station-At a glance 3. Thermal Plant 3.1 Thermal Power Generation 3.2 Coal Based Power Station 3.3 By Products of Power Generation 3.4 Equipments in Thermal Plant 4. Control & Instrumentation Department 4.1 Measurements in Power Plant 4.2 Control Room 4.3Temperature Measurement 4.4 FSSS Logic System 4.5 Pressure Measurement 4.6 Turbine Protection 5. Safety Measures of Thermal Power Plant 6. Gas Plant 6.1 Introduction to Gas Power Plants 6.2 Salient Features of Gas Power Plant 6.3 Gas Plant Operation 6.4 Combined Cycle Power Plant 6.5 Heat Recovery Steam Generator 6.6 Steam Turbine 6.7 Transmission of Generated Power Onto the Grid 6.8 Water Tanks, Natural Gas Pipeline, Control Room 7. Technical Documentation 8. Conclusion 9. References

1. INTRODUCTION

In present time we are seeing that industrial training is necessary for every technical & management student. NTPC organize training programs according to the trade of trainee and section of interest of the trainee. NTPC Dadri is the only national capital power station to have both gas and coal based power generation capacity. It also has the capability to run both the units simultaneously. This report is based on my industrial visit to NTPC Power Plant at Dadri. Through this report, I intend to give a detail about NTPC Dadri power plant and its operation. In this modern era, every area of work say airport, railway, industries, military, shopping malls & even domestic needs depends completely upon power supply. These area needs continuous supply for there operation, therefore there is a need of a unit that can provide continuous power supply to large sections of society. NTPC has its core values as: B C O M I T BUSINESS ETHICS CONSUMER FOCUS ORGANISATION AND PROFESSIONAL MUTUAL RESPECT AND TRUST INNOVATION AND SPEED TOTAL QUALITY FOR EXCELLENCE

2. About NTPC
2.1 Overview Of NTPC

NTPC was set up in the central sector in the 1975 in response to widening demand & supply gap with the main objective of planning, promoting & organizing an integrated development

to thermal power in India. Ever since its inception, NTPC has never looked back and the corporation is treading steps of success one after the other. The only PSU to have achieved excellent rating in respect of MOU targets signed with Govt. of India each year. NTPC is poised to become a 40,000 MW giant corporation by the end of XI plan i.e. 2012 AD. Lighting up one fourth of the nation, NTPC has an installed capacity of 29,394 MW from its commitment to provide quality power; all the operating stations of NTPC located in the National Capital Region & western have acquired ISO 9002 certification. The service groups like Engineering, Contracts, materials and operation Services have also bagged the ISO 9001 certification. NTPC Dadri, Ramagundam, Vindhyachal and Korba station have also bagged ISO 14001 certification. Today NTPC contributes more than 3 / 5th of the total power generation in India. As per Forbes global 2000 ranking for the year 2005, NTPC was 463rd biggest company in the world and 5th biggest Indian company As per ADBs memorandum NTPC is 2nd largest Asian power generator. 2.2 Dadri Station At a Glance NTPC Dadri is model project of NTPC. Also it is the best project of NTPC also known as NCPS (National capital power station). Situated 60 km away from Delhi in the District of Gautama Budh Nagar, Uttar Pradesh. NTPCs Dadri plant is the only one in India to house gas-based as well as coal-based generating units. The station has an installed capacity of 1669 MW of power 840 MW from Coal based units and 829 MW Gas Based Station. The coal-based stations boiler can be fired using 100% furnace oil as well. NTPC Dadri has a total installed capacity of 1669.78 Mega Watts. The coal plant has 4 units which were commissioned one by one from 1991 to 1994 .Each unit has a generation capacity of 210 MW. The Gas plant has 6 units which have a combined capacity of 829.78 MW. It has 4 gas turbine units which were commissioned in 1992 while the 2 steam turbine units were commissioned in 1994. The gas turbine units have a capacity of 130.19 MW each while the steam turbines have a capacity of 154.51 MW each. The station has ~1,130 employees, who have been given accommodation in an integrated township adjacent. The plant is spread over 2,665 acres, making it one of the largest sites in India. The coal unit receives coal from North Karanpura mines located in Jharkhand, almost 1,400km from Dadri. The coal (grade E, calorific value ~4,324-5,089 Kcal/kg) is fed through a rail link. NTPC has a dedicated railway siding that connects Dadri station and the plant. Gas for the plant is supplied by GAIL and is sourced through the HBJ pipeline. The plant consumes 4.7m tones of coal annually, and requires 4.0 mmsmd gases. However, owing to the shortage of gas in India, actual supplies are only 2.5-2.6mmsmcd. Hence, although the

coal plants PLF has been well over 90% since FY05, the gas stations PLF has been much lower, at ~74% for the same period. The station has the largest switchyard in India, with power-handling capacity of 4,500MW. The station is excelling in performance ever since its commercial operation. It is consistently in receipts of meritorious project awards, the coal based units of the station stood first in the country in terms of PLF for the financial year 1999 2000 by generating an all time national high PLF of 96.12 % with the most modern O & M Practices. NTPC Dadri is committed to generating clean and green Power. The Station also houses the first HVDC station of the country (GEP project) in association with centre for power efficiency and Environment protection (CENEEP) NTPC & USAUID. The station has bagged ISO 14001 & ISO 9002 certification during the financial year 1999 2000, certified by Agency of International repute M/s DNV Netherlands M/s DNV Germany respectively. As a part of the infrastructure for the Commonwealth Games, the station is adding coal-based capacity of 980MW (Stage II expansion) consisting of two units of 490MW each.

3. Thermal Plant Thermal power plants convert the heat of heat energy into electric energy, a variety of auxiliary equipments are needed. The auxiliary equipments in a thermal plant are so much that they overshadow the main equipments. The coal handling plant supplies coal to the boiler. The ash formed in the boiler is disposed by the ash handling plant. Air taken from the atmosphere by the action of force induced or draft fan is heated in the preheater before being fed to the boiler. The flue gases pass through dust collector, air preheater and economizer before being discharged to the atmosphere through the energy of coal into electrical energy. Coal is burnt in a boiler which converts water into steam.

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The expansion of steam in turbine produces mechanical power which drives the alternator. To achieve efficient conversion chimney. The boiler vaporizes water into steam; steam is further heated in the super heater and fed to the high pressure turbine. After expanding in high pressure turbine, steam is heated again in a boiler and fed to the low pressure turbine. The exhaust steam from the low pressure turbine is condensed by the condenser and the condensate, along with makeup water, is passed through economizer before being fed to the boiler The coal plant produces a total power of 840MW. The coal-based stations boiler can be fired using 100% furnace oil as well. The gas station has two modules, each consisting of four 130.2MW gas turbines, with a waste-heat recovery boiler and two 154.5MW steam turbines. The station has the largest switchyard in India, with power-handling capacity of 4,500MW. As a part of the infrastructure for the Commonwealth Games, the station is adding coal-based capacity of 980MW (Stage II expansion) consisting of two units of 490MW each. The Dadri plant is 50km away from Delhi, in the state of Uttar Pradesh. Road connectivity to the plant has improved of late, thanks in large part to NTPCs efforts Dadri coal plant has the highest PLFs among all of NTPCs units . The coal unit receives coal from North Karanpura mines located in Jharkhand, almost 1,400km from Dadri. The coal (grade E, calorific value ~ 4,324-5,089 Kcal/kg) is fed through a rail link. NTPC has a dedicated railway siding that connects Dadri station and the plant. Gas for the plant is supplied by GAIL and is sourced through the HBJ pipeline. The plant consumes 4.7m tones of coal annually, and requires 4.0mmsmd gas. However, owing to the shortage of gas in India, actual supplies are only 2.5-2.6mmsmcd. Hence, although the coal plants PLF has been well over 90% since FY05, the gas stations PLF has been much lower, at ~ 74% for the same period. Environment-friendly unit. The plant operates the countrys largest fly-ash disposal facility, with 53m m3 storage capacity. Additionally, Ambuja and Grasim have announced plans to set up cement units near the plant, to use the flyash generated from the plant. As an incentive, NTPC will supply fly-ash to these plants free of cost for the first few months. The thermal station currently produces 1.5m tones of fly-ash daily and some of this is sold in auctions by NTPCs subsidiary NTPC Vidyut Vyapar Nigam. This generates an additional ~ Rs350m income for NTPC annually. The unsold ash has been used to create a flourishing nature park around the plant. The 550-acre ash mound acts as an ecosystem for both flora and fauna. However, churn is evident at the corporate level, where such amenities are not provided and the operating structure is more bureaucratic. Dadri is a benchmark for the best operation practices .Dadri has adopted the best practices for safety, environment protection and maintenance. This is evident from its ISO 9001-2000, ISO 14001 and OSAS 18001 certifications. Additionally, to improve infrastructure around the plant, the company is laying a cement access road. 35% of material used would be fly-ash generated by the plant. The Rs250m-300m expenditure incurred would be capitalized by NTPC. As a part of supply-chain management, the station also assists coals mines in their operations and maintenance. Dadri can add a further 500MW capacity through Brownfield expansion. The existing campus has enough land available to allow an additional Brownfield expansion by

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500MW. Even for the Stage II expansion, only 200 acres additional land for the reservoir was required. 3.1. Thermal Power Generation In a conventional thermal power station, a fuel is used to heat water, which gives off steam at high pressure. This in turn drives turbines to create electricity. At the heart of power stations is a generator, a rotating machine that converts mechanical energy into electrical energy by creating relative motion between a magnetic field and a conductor. The energy source harnessed to turn the generator varies widely. It depends chiefly on which fuels are easily available and on the types of technology used. Thermal power plants are classified by the type of fuel used

Nuclear power plants use a nuclear reactors heat to operate a steam turbine generator Fossil fuelled power plants may also use a steam turbine generator or in the case of natural gas fired plants may use a combustion turbine. Geothermal power plants use steam extracted from hot underground rocks Renewable energy plants may be fuelled by waste from sugar cane, municipal solid waste, landfill methane, or other forms of biomass In integrated steel mills, blast furnace exhaust gas is a low-cost, although lowenergy-density, fuel Waste heat from industrial processes is occasionally concentrated enough to use for power generation, usually in a steam boiler and turbine Solar thermal electric plants use sunlight to boil water, which turns the generator

3.2. Coal Based Power Stations When coal is used for electricity generation, it is usually pulverised and then burned in a furnace with a boiler. The furnace heat converts boiler water to steam, which is then used to spin turbines which turn generators and create electricity. The thermodynamic efficiency of this process has been improved over time. Standard steam turbines have topped out with some of the most advanced reaching about 35% thermodynamic efficiency for the entire process, which means 65% of the coal energy is waste heat released into the surrounding environment. Old coal power plants, especially grandfathered plants, are significantly less efficient and produce higher levels of waste heat. About 40% of the world's electricity comes from coal. 3.3 By Products of Power Generation

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Byproducts of power plant operation need to be considered in both the design and operation. Waste heat due to the finite efficiency of the power cycle must be released to the atmosphere, often using a cooling tower, or river or lake water as a cooling medium. The fuel gas from combustion of the fossil fuels is discharged to the air; this contains carbon dioxide and water vapor, as well as other substances such as nitrogen, nitrous oxides, sulfur oxides, and (in the case of coal-fired plants) fly ash and mercury. Solid waste ash from coal-fired boilers is removed. Ash generated can be re-used for building materials.

3.4 Equipments in Thermal Plant 3.4.1Coal Handling Plant The function of coal handling plant is automatic feeding of coal to the boiler furnace. A grate at the bottom of the furnace holds the fuel bed. Coal is weighed and led to a hopper through a conveyer mechanism. From the hopper it is fed to the gate through some form of stoker mechanism. The stoker may be an overfeed stoker or underfeed stoker depending on whether coal entry is above or below the air entry. It require around 8,400 tons of coal daily. In NTPC there is enough storage of coal to last for 15 days or so. 3.4.2 Pulverizing Plant In modern thermal power plants, coal is pulverized i.e. ground to dust like and carried to the furnace in a stream of hot air. Pulverization is a means of exposing a large surface area to the action of oxygen and consequently helping the combustion. ADVANTAGES 1. The rate of combustion can be controlled and changed quickly to meet the varying load. 2. The banking losses are reduced. 3. The percentage of excess air required is low. 4. Automatic combustion control can be used. 5. A wide variety of even low grade coals can be used. 6. The boiler can be started from cold conditions very rapidly. DISADVANTAGES 1. Investment cost of plant is increased. 2. Explosion hazards exist. Therefore, skilled personnel are required. 3. Auxiliary power consumption of the plant is increased.

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4. A lot of extra equipments, mills, burners are needed. 3.4.3 Draft System The combustion in the boiler requires a supply of sufficient quantity of air and removal of exhaust gases. The circulation of air is caused by a difference in pressure, known as draft. Thus draft is the differential in pressure between the two points i.e. Atmosphere and inside the boiler. A differential in draft is needed to cause flow of gases through the boiler setting. This required differential is proportional to square of the rate of flow. It may be natural or mechanical. NATURAL DRAFT A natural draft is provided by a chimney or stack. Chimney serves two purposes i.e. it produces a draft so that can flow into the boiler and products of combustion are discharged to the atmosphere and it delivers the product of combustion and fly ash to a high altitude so that air pollution is reduced. The gases within the chimney are at higher temperature than that of the surrounding air. MECHANICAL DRAFT Modern large size plants use very huge size boilers of capacity above 1000,000 kg per hour. Such boilers need tremendous volume of air. A chimney cannot provide enough draft for this amount of air. Therefore mechanical draft is necessary. Of course a chimney is always provided. 3.4.4. Boiler A boiler is a closed vessel in which water, under pressure, is converted into steam. It is one of the major components of a thermal power plant. A boiler is always designed to absorb maximum amount of heat released in the process of combustion. This heat is transferred to the boiler by all the three modes of heat transfer i.e. conduction, convection and radiation. They are classified as fire tube boiler and water tube boiler.

FIRE TUBE BOILER This boiler is so named because the product of the combustion passes through the tubes which are surrounded by the water. Depending upon whether the tubes are horizontal or vertical, they are further classified as horizontal or vertical tube boilers. They may be internally fed or externally fed. WATER TUBE BOILER

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In this boiler, water flows inside the tubes and hot gases flow outside the tubes .The tubes are interconnected to common water channels and to steam outlet. Water tube boilers are classified as vertical, horizontal and inclined tubes depending upon whether the tubes are vertical, horizontal or inclined. The number of drums may be one or more. 3.4.5. Steam Turbine A steam turbine converts heat energy of steam into mechanical energy and drives the generator. It uses the principle that a steam when issuing from a small opening attains a high velocity. This velocity attained during expansion depends on the initial and final heat content represents the heat energy converted to kinetic energy. They are of two types impulse and reaction turbine. 3.4.6. Ash Handling Plant Coal contains a considerable amount of ash. The percentage of ash in the coal varies from about 5% in good quality coal to about 40% of poor quality coal. Power plants generally use average or poor quality coal .As a result of this the ash produced by a plant is pretty large. A modern 2000 MW plant produces 5000 tons of ash daily. Of this about 25% is furnace bottom ash and remaining 75% is pulverized fuel ash or dust or fly ash .The small stations use some conveyer arrangement to carry ash to dump sites directly or for carrying and loading it to trucks and wagons which transport it to the site of disposal.. Large stations use more elaborate arrangements and separate systems for the furnace bottom or fly ash. 3.4.7. Condenser Condenser does the job of condensing the steam exhausted from turbine. Thus it helps in maintaining low pressure at the exhaust, thereby permitting expansion of steam in the turbine to a very low pressure. This improves the plant efficiency .The exhaust steam is condensed and used as feed water to the boiler. Maintenance of high vacuum in the condenser is essential for efficient operation. Any leakage of air in the condenser is essential for efficient operation. Any leakage of air into the condenser destroys the vacuum. As it is impossible to eliminate air leakage completely, a vacuum pump is necessary to remove the air leaking into condenser. 3.4.8. Cooling Towers The condenser needs huge quantity of water to condense the steam. Roughly one kg of steam needs 100 kg of cooling water for the condenser. Such large requirement of water can be met if the plant is situated by the side of a big river with sufficient flow. Water is led into the plant by means of circulating water pumps and, after passing through the condenser, is discharged back into the river. It is necessary to establish the correct relative position of the intake and outfall.

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A cooling tower is a steel or concrete hyperbolic structure having a reservoir at the bottom for storage of cooled water. Warm water is led to the top. Air flows from the bottom to top. The water drops falling from the top come in contact with air, lose heat to the air and get cooled. 3.4.9 Economizer Flue gases coming out of the boilers carry lot of heat. An economizer extracts a part of this heat from the flue gases and uses it for heating feed water. The use of an economizer results in saving the coal consumption and higher boiling efficiency, but need extra investment and increase in maintenance costs and flour area required for the plant. Economizer is used in all modern power plants. 3.4.10 Relay A relay is n electrical switch that opens and closes under the control of another electrical circuit. In the original form, the switch is operated by an electromagnet to open or close one or many sets of contacts. It was invented by Joseph Henry in 1835. Because a relay is able to control an output circuit of higher power than the input circuit, it can be considered to be, in a broad sense, a form of an electrical amplifier. Since relays are switches the terminology applied to switches is also applied to relays. A relay will switch one or more poles, each of whose contacts can be thrown by energizing the coil in one of three ways:

Normally-open (NO) contacts connect the circuit when the relay is activated; the circuit is disconnected when the relay is inactive. It is also called a Form A contact or "make" contact. Normally-closed (NC) contacts disconnect the circuit when the relay is activated; the circuit is connected when the relay is inactive. It is also called a Form B contact or "break" contact. Change-over (CO), or double-throw (DT), contacts control two circuits: one normally-open contact and one normally-closed contact with a common terminal. It is also called a Form C contact or "transfer" contact ("break before make"). If this type of contact utilizes make before break" functionality, then it is called a Form D contact.

Motor Protection Relay This relay detects how much is the positive sequence component, how much is negative sequence component and how much is zero sequence component. In case negative sequence component and zero sequence component (earth fault) goes above a certain value, it trips the Circuit Breaker.

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Fig 2.2 Relays

3.4.11. Feed Water Heater A feed water heater is a power plant component used to pre-heat water delivered to a steam generating boiler. Preheating the feed water reduces the irreversibility involved in steam generation and therefore improves the thermodynamic efficiency of the system. This reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when the feed water is introduced back into the steam cycle. In a steam power plant, feed water heaters allow the feed water to be brought up to the saturation temperature very gradually. This minimizes the inevitable irreversibility associated with heat transfer to the working fluid (water). 3.4.12. Super heater and re heater Fossil fuel power plants can have a super heater or re heater section in the steam generating furnace. Nuclear-powered steam plants do not have such sections but produce steam at essentially saturated conditions. In a fossil fuel plant, after the steam is conditioned by the drying equipment inside the steam drum, it is piped from the upper drum area into tubes inside an area of the furnace known as the super heater, which has an elaborate set up of tubing where the steam vapor picks up more energy from hot flue gases outside the tubing and its temperature is now superheated above the saturation temperature. The superheated steam is then piped through the main steam lines to the valves before the high pressure turbine. Power plant furnaces may have a re heater section containing tubes heated by hot flue gases outside the tubes. Exhaust steam from the high pressure turbine is rerouted to go inside the re heater tubes to pickup more energy to go drive intermediate or lower pressure turbines. 3.4.13. Air Preheater

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An air preheater (APH) is a general term to describe any device designed to heat air before another process (for example, combustion in a boiler) with the primary objective of increasing the thermal efficiency of the process. They may be used alone or to replace a recuperative heat system or to replace a steam coil. The purpose of the air preheater is to recover the heat from the boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas. As a consequence, the flue gases are also sent to the flue gas stack (or chimney) at a lower temperature, allowing simplified design of the ducting and the flue gas stack. It also allows control over the temperature of gases leaving the stack (to meet emissions regulations, for example). There are two types of air preheater for use in steam generators in thermal power stations: One is a tubular type built into the boiler flue gas ducting, and the other is a regenerative air preheater. These may be arranged so the gas flows horizontally or vertically across the axis of rotation. 3.4.14. Protection and control Equipment In the thermal power plant, protection and control equipments controls and protects all the equipments of power generation process from emergency or unexpected conditions. Devices protected are such as Boiler, turbine etc. Control devices measure and maintain other parameters such as temperature, pressure etc. The turbine protection system can be actuated by two methods-Hydraulic trip system and Electrical Trip System. Both the systems, when initiated, act on hydraulic control system and cause trip oil pressure to collapse which in turn closes the emergency stop valves, Interceptor valves and control valves.

4. Control & Instrumentation Department

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Control and Instrumentation department plays the most significant role in a thermal power plant. It consists of engineers from Electronics and Communication Branch. This department is further divided into 1. Operations Department and 2. Maintenance Department Operations Department looks after the successful operation and running of power plant. This department takes care of plant running conditions. They are responsible for providing data at control room regarding the plant conditions and parameters such as temperature etc. Maintenance department is responsible for all the maintenance related tasks of plant and control systems. Thermal power plant consists of control systems used for controlling the plant devices. These control systems are maintained by C&I Department. 4.1. MEASUREMENTS IN POWER PLANTS In a power plant number of measurements is made. These can be divided into Electrical measurements current, voltage, power, frequency, power-factor etc., Non-Electrical parameters flow of feed water, fuel, air and steam with correction factor for temperature steam pressure and steam temperature-drum level measurement radiation detector smoke density measurement dust monitor.

4.2. Control Room From the control room, the plant operators monitor and operate the facility, via the plants Distributed Control System, with the click of a mouse, viewing graphic representations of all MEC systems on various screens. The system gives operators both audible and visual signals to keep them informed of plant conditions at all times and to determine when preventative maintenance is required. Control Rooms are connected to plant via optical fibers. They receive real time data regarding the plant conditions such as boiler temperature, pressure, fan speed etc. They are used to control and monitor all the plant conditions and various parameters.

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They are used to trip boiler, primary fan, turbine and other power plant equipments in case of their regarding parameters crossing the safe limits.

4.3. Temperature Measurement Temperature Measurements in a power plant is a very important task. If temperature of any of the plant equipments rises above its safe limits, it would cause serious security problems and can be a threat to plant and its workers. 4.3.1. Temperature Measurement Devices For the purpose of temperature measurement, various devices are used depending on the suitability and applicability of measuring devices. Some of them are thermocouples, resistance thermometers, thermistors, bimetallic thermometers and acoustic pyrometers. Thermocouple Thermocouple is based on seeback effect which states that when heat is applied to a junction of two dissimilar metals an emf is generated which can be measured at the other junction.

Fig. A thermocouple junction Resistance Thermometer The resistance of a conductor changes when its temperature is changed. This property is utilized to measure the temperature. Rt = Ro (1+dT) WHERE = Temperature co-efficient of resistance

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dT = Temperature difference

Fig. Resistance Temperature Detector Thermistors Thermistors are generally composed of semiconductor materials. They have a negative coefficient of temperature, so resistance decreases with increase in temperature. The coefficient is as large as several % per degree Celsius. This allows the thermistors to detect small changes in temperature which could not be observed with thermocouples or RTDs. So these are used for precision temperature measurements control and compensation. Bimetallic Thermometers Bimetallic Thermometers works on the principle that all metals expand or contract with temperature and the temperature coefficient is not the same for all metals and so their rate of expansion or contraction are different.

Fig. Bimetallic Thermometer

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Bimetallic devices are extensively used in process industries for local temperature measurements. These are also used as cut out switch in electrical apparatus by monitoring current flow. Acoustic Pyrometer Acoustic pyrometers work on the principle that the velocity of sound in a medium is proportional to the temperature. Gas Temperature = [ Distance / (Time * B) ]^2 Where, B=constant 4.4. FSSS Logic System FSSS stands for Furnace Safeguard Supervisory System. It has the following major tasks to perform: Satisfactory Boiler Startup Startup Of Individual Oil Systems Operation Of fuel firing subject to certain conditions Protection and interlock of oil/coal system

4.5 Pressure Measurement Pressure is defined as force per unit area. Pressure measurement is very important as high pressure may cause accidents. For example, if pressure inside a boiler rises above the safe limits then it may cause bursting of boiler.

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Pressure of one normal(standard) atmosphere is known as standard pressure. Mathematically it can be expressed as: 101325 Pa / 101.325 kPa 1013.25 mbars 14.696 psia 29.921 in.Hg / 760 mmHg @ 0oC (32oF) 407.5 in.H2O / 33.958 ft.water @ 20oC (68oF)

4.4.1. Pressure Sensors

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Fig. Various Pressure Sensing Devices In the above figure, The basic pressure sensing element (A): C-shaped Bourdon tube (B): a helical Bourdon tube (C): flat diaphragm (D): convoluted diaphragm (E): capsule (F): a set of bellows Bourdon Tube

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Bourdon tube is a sealed tube that reflects in response to applied pressure. It provides fairly large displacements (except diaphragms).It is useful in mechanical gauges and for electrical sensors that require a significant movement. 4.6 Turbine Protection The turbine protection system, as the name suggests protects the turbine from any hazardous conditions. The turbine protection system can be actuated by any of the following trip systems: Hydraulic Trip System Electrical Trip System Both the trip systems, when initiated, act on the hydraulic control system and cause trip oil pressure to collapse which in turn closes the Emergency stop valves, Interceptor valves and control valves. In a turbine protection system, two trip solenoids are provided in the hydraulic circuit, which get trip signals from the electrical system. Actuation of any one solenoid is sufficient to trip the turbine. The electrical system is configured as a 2-channel system. Each channel is realized in a Processing Unit. Both the processor units are completely independent of each other and input modules, processor module and output modules reside on each. Each channel having two processors Unit with one processor in hot standby mode. Realization of 2 out of 3 trip logic is carried out in the processor. Both the channels are tested periodically even while the turbine is running. Cyclic testing is done automatically at preset intervals

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Fig. Turbine protection system

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5. Safety Measures In a thermal power plant, care is taken regarding the safety of the workers in the plant. All measures are to taken to ensure that there is no accident or any sort of mishappening takes place. It is very important to maintain the plant safety so as to maintain a good workable atmosphere among the employees. History gives us many examples where hundreds of lives have been lost and loss of millions of money has occurred due to industrial accidents. Accidents like Bhopal Gas Leakage; Mexico etc have not only destroyed peoples lives but also impacted the future generations in the area. Effects of these accidents can be still seen in such areas. Children born in these areas are generally born with some sort of genetic disorder. For the individual safety of workers, following steps are taken: They are given helmets to wear before entering the plant. They are supposed to enter the plant only if wearing shoes. They are given special training for lifting heavy loads. Annual training is given to workers for emergency cases such as gas leakage etc.

On the plant level, following steps are taken for safety: Regular maintenance of plant equipments. Carrying on pseudo tests on all equipments such as boiler, turbine etc. Educating labors about what to do in case of emergency such as gas leakage. Ensuring the quality and durability of devices used. Taking extra care in handling and maintenance of volatile materials such as chlorine gas.

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6. GAS PLANT

6.1 Introduction To Gas Power Plants

The development of the sector in the country, since independence has been predominantly through the State Electricity Boards. In order to supplement the effects of the states in accelerating power development and to promote power development on a regional basis to enable the optimum utilisation of energy resources, the Government of India decided to take up a programme of establishment of large hydro and thermal power stations in the central sec tor on a regional basis. With this in view, the Government set up the National Thermal Power Corporation Ltd., in November 1975 with the objective of planning, construction, commissioning, operation and maintenance of Super Thermal and Gas Based Power projects in the country. The availability of gas in a large quantity in western offshore region has opened an opportunity to use the gas for power generation, which is an economical way and quicker method of augmenting power generating capacity by natural gas as fuel in combined cycle power plant in a power deficit country like ours. With this intention in mind the Government asked NTPC to take up the construction of Kawas, Auraiya, Anta, Dadri and Gandhar Gas Power Project along the HBJ Gas pipe line.

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The power plant consists of gas turbine generating units waste heat recovery boilers, steam turbo generator, ancillary electrical and mechanical equipments. The power generated at this power station is fed over 220 KV AC transmission system associated with this project to distribute the power in the various Regions. In the Power Sector, gas turbine drive generators are used. Gas turbines range in size from less than 100 KW up to about 140.000 KW. The gas turbine has found increasing application due to the following potential advantages over competive equipment. Small size and weight per horsepower Rapid loading capability Self-contained packaged unit Moderate first cost No cooling water required Easy maintenance High reliability Waste heat available for combined cycle application. Low Gestation Period Low Pollution Hazards The function of a gas turbine in a combined cycle power plant is to drive a generator which produce electricity and to provide input heat for the steam cycle. Power for driving the compressor is also derived from gas turbine.

6.2 Salient Features of NTPC DADRI Gas Project DADRI GBCCPP-STAGE I (817MW) General Layout Plan In the main plant block two modules, each consisting of two GTGs placed on each side of 2 STGs. The central control room is located towards west of the ST hall. The transformer yard Is on the wester side of the turbine hall, with switchyard further down west. Induced draft cooling towers have been located considering the proper flow of cooling water. Nearer to main power house & convenient routing of open return channel to CW pump house. The 220/400 KV switchyard has been located in front of the power station.

29

The 220 KV switchyard control room is accommodated in the central control room itself. Space has been kept for liquid oil installation and oil unloading facilities. The GAIL terminal for receiving gas is located within boundary of plant site.

6.3 Gas Plant Operation

Gas Turbine, WHRB, Steam Turbine Starting Modes

Basic conditions for plant operation are as follows: Start up or shut down of G/T, WHRB and S/T of each module is performed separately from the other module (except for S/T gland steam back-up and heating steam back up systems). Start up/shut down mode is selected freely form among those mentioned. The start up/shut down procedure for WHRB and S/T here mainly describes operating procedure for G/T by-pass damper, WHRB inlet damper and remote operated valve necessary for start up and shut down from G/T exhaust gas admission to WHR till rated load operation of S/T. For detail operating procedure for G/T WHRB, S/T auxiliaries and remote operated valve following procedures are followed.

30

Start up Mode The start up mode of G/T, S/T and WHRB shall be selected from among the following as a rule through various other start up modes are conceivable according to power demand and operating principle. Normal start up mode Rapid start up mode G/T/WHRB additionally start up mode Single G/T/WHRB start up mode

6.4 Combined-Cycle Power Plant

Power Generation: Air Inlet The amount of air needed for combustion is 800,000 cubic feet per minute. This air is drawn though the large air inlet section where it is cleaned, cooled and controlled, in order to reduce noise. Turbine-Generators: The air then enters the gas turbine where it is compressed, mixed with natural gas and ignited, which causes it to expand. The pressure created from the expansion spins the turbine blades, which are attached to a shaft and a generator, creating electricity. Each gas turbine produces 185 megawatts (MW) of electricity. The blades are attached to a rotor, which spins the generator, and makes electricity. Think of a generator as a huge spinning magnet inside a coil of wire. As the magnet spins, electricity is created in the wire loops.

31

6.5 Heat Recovery Steam Generator (HRSG)

The hot exhaust gas exits the turbine at about 1100 degrees Fahrenheit and then passes through the Nooter Erickson, Heat Recovery Steam Generator (HRSG). In the HRSG, there are 18 layers of 100-foot tall tube bundles, filled with high purity water. The hot exhaust gas coming from the turbines passes through these tube bundles, which act like a radiator, boiling the water inside the tubes, and turning that water into steam. The gas then exits the power plant through the exhaust stack at a much cooler 180 degrees, after having given up most of its heat to the steam process. About 1 million pounds of steam per hour is generated in this way and sent over to the steam turbine through overhead piping.

32

6.6 Steam Turbine

The steam turbine is a Siemens Westinghouse KN Turbine Generator, capable of producing up to 240 MW. It is located on top of the condenser, across from the cooling tower. Steam enters the turbine with temperatures as high as 1000 degrees Fahrenheit and pressure as strong as 2,200 pounds per square inch. The pressure of the steam is used to spin turbine blades that are attached to a rotor and a generator, producing additional electricity, about 100 megawatts per HRSG unit. After the steam is spent in the turbine process, the residual steam leaves the turbine at low pressure and low heat, about 100 degrees. This exhaust steam passes into a condenser, to be turned back into water. By using this combined-cycle process, two gas turbines and one steam turbine, we can produce a total of about 600 megawatts of electricity.

6.7 Transmission of Generated Power Onto the Grid Transformers

33

The Gas Turbine and Steam Turbine generators produce power at 13,000 volts. The transformers take the generated 13,000 volts and transform them to 230,000 volts, which is the required voltage needed for transmission to the nearby tower that sends power to the substation. A small amount of generation is directed to Auxiliary transformers which transform the generated voltage to a lower voltage, so it may be used by the plant to power our own pumps, fans, and motors. The Metcalf Energy Center requires 12 15 megawatts to operate.

Switchyard From each transformer, the power passes underground into our switchyard. The power from all of the generators comes together there, where it is measured, metered and directed onto the grid. The proximity of the site to a large, existing PG&E substation makes it a good place to build a power plant and the nearest transmission tower is only about 200 feet away.

Condenser and Cooling Tower The purpose of the condenser is to turn low energy steam back into pure water for use in the Heat Recovery Steam Generator. The purpose of the cooling tower is to cool the circulating water that passes through the condenser. It consists of ten cells with large fans on top, inside the cone-like stacks, and a basin of water underneath. We process and treat the Title 22 recycled water after receiving it from the City, before using it in our cooling tower. The cool basin water absorbs all of the heat from the residual steam after being exhausted from the steam turbine and it is then piped back to the top of the cooling tower. As the cool water drops into the basin, hot wet air goes out of the stacks. Normally, hot moist air mixes with cooler dry air, and typically a water vapor plume can be formed, one that may travel hundreds of feet in the air and be seen from miles away. The California Energy Commission considered this visually undesirable in this community so we added a Plume-Abatement feature, louvers along the topsides of the tower that control the air flow. The cooling tower evaporates about three-fourth of the processed, recycled water, then we send about one-fourth of it back through the sewer lines for re-treatment by the City. The Metcalf Energy Center purchases 3 to 4 million gallons per day of recycled water from the City of San Jose. Evaporation of this water assists the City in adhering to their flow cap limits and helps to protect the sensitive saltwater marsh habitat of the San Francisco Bay environment from receiving too much fresh, recycled water.

34

6.8 Water Tanks, Natural Gas Pipeline, Control Room

Water Tanks The largest tank is the Service Water tank. It contains 470,000 gallons of water to be used for drinking, fire fighting and for the high purity water train. The water from the service water tank is pumped to the water treatment building where it then passes through a reverse osmosis unit, a membrane decarbonater, and mixed resin bed demineralizers to produce up to 400 gallons per minute of ultra pure water. The pure water is then stored in the smaller 365,000-gallon tank until it is turned into steam for making electricity. Natural Gas Natural gas fuels the combustion turbines. Each turbine can consume up to 2,000 MMBTU per hour. The fuel comes from the major high pressure natural gas pipeline that runs along the east side of Highway 101, less than 1 mile to the east of our site. During construction, Horizontal Directional Drilling was utilized with careful coordination with many local authorities. The pipeline was built 60 feet underground and passed under highways, creek, train tracks, and environmentally sensitive areas. The pipeline enters the site just behind the water tanks, where equipment regulates and measures the natural gas composition, flow and pressure. Gas compressors pump the natural gas though the facilities fuel gas system where it is delivered to the gas turbine and the HRSG duct burners at the proper temperature, pressure and purity.

Control Room From the control room, the plant operators monitor and operate the facility, via the plants Distributed Control System, with the click of a mouse, viewing graphic representations of all MEC systems on various screens.

35

The system gives operators both audible and visual signals to keep them informed of plant conditions at all times and to determine when preventative maintenance is required.

36

7. Technical Documentation
SALIENT FEATURES :

i) ii) iii) iv)

Type of Station Station Capacity Fuel Source, Gas Transportation Consumption Cooling Water source

: : : : : :

Combined Cycle Power Plant 817 MW(2(131 x 2+146.5))130.5+154.51 Main - Natural Gas Alternate fule - HSD Hazira Through HBJ Pipe Line 4.0 MCMD Upper Gange Canal Dehra headwork. During closer of UGC through network of tubewells.

v)

vi) vii)

Startup Power Heat rate- open cycle Combined cycle Specific Gas Consumption

: : : : : :

Black Start DG set 2.6 MVA capacity. 2692 Kw / Kwh 1748 Kw / Kwh Open cycle - 0.3167m3/ Kwh Combined Cycle - 0.205m3/ Kwh 100% MCR

viii)

HP/LP bypass capacity (for steam turbine only)

ix)

Efficiency Open cycle Combined cycle Time required form barring Speed to synchronisation : 4 min 16 min. 9 min. Time required form synchronisation To base load at normal Gradient : At Fast Gradient : : : 32% 48.33%

37

CONTROL AND INSTRUMENTATION

1.0 1.1

C&I SYSTEM : SAILENT FEATURE Supplier/ make : siemens AG

1.1.1 Type

Digital Process control teleperm-ME

Sub-Systems

a)

Automation sub system AS220E/EHF Functions : Signal conditioning, Automation, controls, Monitoring & Protection interlocks.

AS220 EHF Special Features :

Triple redundant central processing units for processing signals in two out of three logic. b) Sub- system AS 231 Functions : Monitoring, Alarms and calculation for GTs

c)

Sub system OS254 Functions

Centrialised operation & monitoring.

1.1.2. Information system Madam - S Type : SICOMP M 26

38

Functions

Monitoring, information displays logging and Performance calculations.

1.1.3 Oscillostore Functions

Sequence of events recording.

1.1.4 Bus System Type Functions

: :

CS275 Inter connection (coupling) of various C&I Systems.

1.1.5. Electro Hydraulic governing system Controls for GT units. Type : Iskamatic

1.1.6 Gas Filtration Plant Instrumentation Supplier : M/s. Siemens AG Make Functions : : Alpha, Germany Gas filtration plant (measurements and control)

1.1.7 Uninterupted Power Supply (UPS) Supplier : Siemens AG Make : Gustav Klien

1.1.8 CCR Instrumentation Supplier/ make Type

: :

Siemens, AG Mosaic Tile system- 8RU

1.2.0 Supplier/ Make 1.2.1 EAST Pkg

: :

BHEL Electronic Automation System for turbine

39

- Type - Functions

ISKAMTIC : Steam Turbine Electro Hydraulic governing system cotrol, seal steam controls, measurements autosynchroniser and load shedding relay.

1.2.2 HP/LP bypass system Controls. Type :

ISKAMATIC.

1.2.3 Steam and water analysis system Supplier : BHEL

Primary sample conditioning system Make Analysers section : : Lowe UK Polymetron France

No of analysers (per module) Silica Dissolved Oxygen Conductivity PH Sodium Hydrazine : : : 5 Nos. 4 Nos.

19 Nos. : : : 6 Nos. 5 Nos. 2 Nos.

Recorders

19 Nos.

Alarm System Type : Microprocessor based

40

Make

Rochester Instruments, Scotland.

Chiller units Make Capacity : : Conair Churchill 2 x 100%

3.1

Fire protection system Supplier Sub vendor Type i) CO2 system

: :

Siemens Ltd. Techno Equipment

For GT combustion chambers lube oil skid and fuel oil injection skid

ii)

Halon System

For CCR, Computer room, control equipment rooms and electrical switchgear.

iii)

Deluge System

For transformers.

2.0 2.1

System Details AS 220 E :

AS 220 E is the basic system with a single central processing unit where open loop controls and protections are implemented. I/O modules are used for drive controls & close loop controls.

2.2

AS 220 EHF :

The AS 220 EHF

is functionally divided into a triple redundant central unit.

Central Processors

2 out of 3 technique with complete self

41

Monitoring microprogrammed. Data bus Power supply : : 8 bit

+ 24 V DC, 25 amps, redundant

No of I/O modules which can be plugged max 162

2.3 0S254EK The operation & monitoring system OS254EK is bus coupled component of the Teleperm ME. Two no. of OS254EK are provided per module.

TECHNICAL DATA Hardware : (1) (2) (3) (4) (5) (6) Central Processor Data bus Main memor(DRAM) Dot graphics Operation Channel Printer : : : : : : Microprogrammed 16 bit wide 2048 Bytes Dot resolution with max 64 x 1000 dots max 2

1 No. each.

Software : (1) Information mode(NOBI) : Plant overview, area display, group displays, Sub ordinate group display, individual display, Functions display.

Display Type

Maxm. Nos possible Area Groups per area

: :

12 24

42

Control tiles & displays per gourp 16 Updating cycle 21 Sec 250 ms 400 msec <2 sec

- Output cycle for process operations commands: -

Time interval between command output & status Feed back display : Display selection time

(2)

Information mode FUBI Display type- large size display No of possible Alarms Updating Display selection time : : : 6000 sporadic < 2 sec

(5)

Information mode KUBI Curve displays Acquisition cycle OS254 memory Features

: : : :

IH,2H, 4H, 8H 2 sec. 2048 K bytes

Two partial systems configured identically Heirarchial structure organisation No of monitors / module No of printers : : 4 Nos. 2 Nos.

2.4

Oscillostore :

Oscillostore E2 is a compact signal recording & printing system which continuously Monitors binary signals and statuses.

43

Capacity Resolution Sequential memory :

: :

Max. 256 binary signals 1 msec.

Approx. 800 signals

2.5 Data Acquistion System Madam- S (Sicomp M-26) Technical Data Central Processor : : ZE 02 16 Parallel Processing RAM Data retention after Power failure Serial interfaces : 3xX.27 or TTY terminal 1xV.27 or TTY printer Floppy disc drive Hard disk Magnetic Tape cartridge Binary Inputs Capacity Analog inputs capacity : : : : : 1.2 MB FP 41 E 350 MB MK 82 Q 150 MB 3650 600 : : 8 MB.

>5 hrs. at max. capacity

Features available i) ii) iii) iv) v) vi) vii) viii) Bar chart display Trend display 8 mts, 80 mts, 8H Mimics Alarms information Status display of binary signals Logging of parameters Through Operating log 0.5H, 1.0H, 2.0H. Sequence of Eventsrecording through incident review log. Performance calculations

44

ix)

Other important logs Alarm & switching logs Binary signal status log Analog group log Event count log Alarm count log

Operating System

BS-M & Amboss- G

2.0

System Configuration : : : : 12 63 20

No of group Controls No of OLCS No of CLCS System Redundancy 1) 2) 4.0 4.1

AS 220 EHF used for protection (GTs, WHRBs & STs) is triple redundant. Parallel operation for all subgroup & group controls are available from CRT and pushbutton on the MIMIC panel. Protection interlocks : Gas Turbine

Gas Turbine Protection Trip initiating Signals ____________________________________________________________________ sl.no. Description Set Value Remarks____

1.

Overspeed (Emergencygovernor operated)

>55 Hz

Mech. Trip

2.

Axial shift high

>+/- 1 mm

mech. Trip

45

(Thrust bearing trip-operated) 3. Compressor anti surge protection <30 m bar Activates at speed >425rpm 4. Bearing temp. V. high (turb./compressor/ Generator bearings) 5 Bearing vibration V. high (Trub./Compressor/ Generator Bearings) 6. 7. 1. Flame off Bearing oil pressure --<0.7 bar -2 out off 2 logic 2 out of 2 logic >11 mm/sec -- do ->120oC 2 out of 2 logic

Fire protection i) Lub oil tank/F.O. inj. Skid > 70oC ii) Comb. Chambers > 90oC --Variable set point (based on

9. 10

Manual Trip Trub. Outlet temp. V.high

2 out off 2 logic

ambient temp.) 11. Fuel gas pr. Low < 12.2 bar

Shut down- Initiating Signals

L.O. oil tank level low

Salient feature of Protection system

46

1.

Redundancy in sensors for important protection functions. (bearing temp., Turb outlet temp, flame protection , fire protection.) Processing of processing functions in 2 channels with 2 out of 2 voting logic. In the envent of fault in one channel, protection logic is automatically changed to 1out of 1 logic. Processing of protection functions in central unit with 2 out of 3 voting logic.

2.

3.

4.1.1. GT Auxillaries. I) i) ii) iii) iv) v) vi) vii) viii) 3) i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) 4) 1) 2) 3) Diffusion burner valves open s on Turbine outlet temp. calculated Load rejection Air controller (L & R) on Manual Fuel Gas pressure < 14.5 bar Air controller fault Fuel oil ESV open Mixed operation active Fuel oil feed/ Return valve > 0 % Premix burner valves Conditions for pre-mix burner open Turbine outlet temp. calcualted > 500 oC Air controller (L&R) on Auto Fuel Gas Pressure > 14.5 Bar Turbine speed >49 Hz. Fuel gas Diffusion burners open Fuel oil ESV Closed Air controller - No Fault Mixed operation not active Fuel Gas shut off - No fault Pilot burner control on Pilot burners open Pilot burner valves Release conditions for open Fuel Gas ESV open 220 KV circuit brearer on Speed > 49 Hz. <490oC

47

4.2.0 WHRB Trip initiating signals (provided GT is in operation ) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) LP drum level < - 700 mm (2/3 logic) LP drum level high > 950 mm (2/3 logic) LP circulating pump DP <0.8 bar(2/3/logic) All CEPs off after 10 Sec. Time delay. All HPBFPs off after 10 sec. Time delay. All LPBFPs off after 10 Sec. Time delay. GT trip triggered. Gen. Circuit breaker (GT) open Unit circuit breaker (GT) open Manual trip ch.1 Manual trip ch. 2 Steam temp. > 5600C LP by P. prot. HP by P. Prot. HP drum level <-750 mm (2/3 logic) HP drum level > 910 mm (2/3 logic) HP circulating pump DP < 0.5 bar (2/3 logic)

4.2.1 WHRB Auxillaries i) HPCC pumps Rleases for start of pump _____________________________________________________________________ S.NO. Description set value Remarks

______________________________________________________________________

48

1.

HP drum level. Or blr. Damper > Min 3 Not closed Trip initiating signals - 650 mm

2/3 logic

Trip initiating signals. ______________________________________________________________________ S.NO. Description set value Remarks

______________________________________________________________________ 1. 2. 3. Motor bg. Temp Hi Motor winding temp Hi HP Drum level low > 80 Deg.C > 110 Deg.C < (-750 mm) Time delay 2/3 logic 2- Sec. 4. HPCC pumps DP < 0.5 bar

II)

LPCC pumps

Releases for start of pumps _____________________________________________________________________ S.NO. Description set value Remarks

_____________________________________________________________________ 1. LP Drum Level or Blr. Dampers not closed > -600 mm 2/3 logic

Trip initiating signals. _____________________________________________________________________ S.NO. Description set value Remarks

_____________________________________________________________________ 1. LP drum level low <-700 mm 2/3 logic time delay

49

2 sec. 2. LP circ. Pumps DP < 0.8 bar Time delay 3 sec after start of pps 2/3 logic

III)

HP drum level interlocks.

____________________________________________________________________ S.NO. set value Action

____________________________________________________________________ 1. <-750 mm Drum level low protection HPCC pumps trip WHRB trip. 2. <-650 mm HP drum level low Alarm HP drum drain valves protection close 3. 4. 5. 6. >-650 mm >-350 mm <-300 mm. > 710 mm. Release for HPCC pumps startup. Fill Level Release for gas in HP drum level high alarm HP drum drain valves Auto open 7. 8. > 760 mm < 760 mm Protection open HP drum drain valves. Release for opening HP feed control station isolation valves 9. > 810 mm HP drum level V. high alarm Protection close HP feed control station isolating valves. 10. 11. > 860 mm >910 mm Protection close HP economiser inlet valve HP drum level high Protection WHRB Trip HPBFPs Trip. 12. < 910 mm Release for HPBFPs start.

50

(iv) LP drum level interlocks ____________________________________________________________________ S.NO. set value Action

____________________________________________________________________ 1) <-700 mm Drum level low protection WHRB trip LPCC Pumps trip 2) <-600 mm LP drum level low Alarm Protection close LP drum drain valve. 3) 4) 5) 6) <-300 mm > 200 mm > 750 mm > 800 mm Release for Gas -in LP drum drain valves through SLC drain & vents LP drum Level high alarm Auto close LP LP drum level high alarm Protection close LP drum drm. valve 7) < 800 mm Release for opening LP feed control station isolating valves. 8) > 850 mm LP drum level v. high alarm potection close LP feed control station isolating valves 9) 10) > 900 mm > 950 mm LP economiser inlet valve protection close. LP drum level high protection WHRB trip LP BFPs trip. 11) < 950 mm Release for LPBFPs start.

4.3 i)

Water steam Cycle Equipment : Cooling water pumps Releases for start of Pump :

51

___________________________________________________________________ S.NO. Description set value Remarks

___________________________________________________________________ 1. CW inlet & outlet V/Vs ond. Left open OR CW inlet & outlet V/Vs cond. Right. 2. 3. 4. Disch. VV Sump level Bearing Temp.(pump/ motor) Closed > 207.8 m

Trip initiating signals _____________________________________________________________________ S.NO. Description set value Remarks

_____________________________________________________________________ 1. 2. 3. 4. 5. 6. 7. 8. Sump level too low Pump bearing temp. v. high Motor bearing temp. v. high Discharge valve closed Bearing vibration v. high Discharge header pressure v. high Discharge pressure low Condenser inlet/ outlet valve closed Two out of two logic. Sequential trip. -

CW pump discharge valve closes on protection after pump tirp.

ii) ACW Pumps Releases for start of Pumps .

52

____________________________________________________________________ S.NO. Description set value Remarks

____________________________________________________________________ 1. 2. 3. Suction V/V open Disch. V/V closed or one /more ACW pps on. ACW suct. Pr.>Min or(ACW n-let Hdr. Pr.>Min & (One/ more ACW pp ON & its disch. Valve open) (interconnecting v/v also in case of CWP3) -

Trip initiating signals ____________________________________________________________________ S.NO. Description set value Remarks

____________________________________________________________________ 1. 2. Suction V/V closed Discharge V/V closed after time delay of 15 sec. 3. Suction pr. < min 0.25 2/3 logic

iii)

C.E.P. Trip initiating signals

53

1. 2. 3.

Hotwell level very low <- 700 mm (2/3 logic) Pump discharge pressure low < 10 bar after delay of 10 Secs. Condensate flow after GSC <28 kg/s after delay of 180 secs. Release for start of pump :

1. 2. 3. 4. 5.

Hotwell level > 1200 mm Suction valve open Discharge valve closed or any one CEP on or Discharge header pressure >10 bar Condensate flow > 31 kg/s or Min. recirculation CV bypass open or GSC bypass valve open or GSC inlet & outlet valve open.

iv) L.P.B.F.P. Release for start of pump 1. 2. Suction valve open Discharge valve closed or discharge header pressure > 10 bar Trip initiating signals 1. 2. 3. v) :

LP drum [v] Boiler 1 > 950 mm LP Drum [v] Boiler 2 > 950 mm Dearator [v] < MIN2 H.P.B.F.P. Release for start of pump

____________________________________________________________________ SL.NO. DESCRIPTION SET VALVE

____________________________________________________________________ 1) (Disch. Valve close & Disch. Valve int. byp closed) OR disch. Hdr. Pr.>Min 2) 3) 4) L.O. pr. Common hdr. >min Recirculation v/v open lub oil tank level > min 50 bar 2 bar open 600 mm Closed

54

5)

Suction valve open

open

Trip initiating Signals

____________________________________________________________________ S.NO. Description set value Remarks

____________________________________________________________________ 1) 2) 3) 4) HP drum level WHRB3 >Max 4 >910 mm HP drum level WHRB4 >max 4 > 910 mm Deacrator [v]<Min2 Bearing temp. v. high>max2 (BP/BFP/Motor brgs.) 5) 6) 7) 8) Motor wdg. Temp v. high 6 suct- disch diff temp v.high L.O. com. Hdr. Pr. V. low Recirc.VIv not open & suct. Flow <min 110oC 15oC 1 kg/cm2 23.6 kg/s 2/3 logic 1/2 logic - 1900 mm 85oC 2/3 logic 2/3 logic 2/3 logic -

iv)

Seal Oil pump I,

Auto start on PP.NO. 1 selected & seal oil pressure <MIN

v) vi) vii)

Seal oil Pump 2 Auto start on PP. No. 2 selected & seal oil pr. <MIN Seal Oil pump 3(DC) Auto start on Seal Oil pr. < 8 kg/cm2 Vacuum breaker valve Protection open on Fire protection ch. 1 operated

55

Fire protection ch.2 operated viii) Turning Gear Protection open initiating signals : 1. 2. 3. 4. ix) Fire protection ch 1 operated Fire protection ch 2 operated Jacking oil pump 1 on or JOP 2 on, speed < 0.15 hz and seal ring TE(EE) pressure < MIN Vacuum breaker

R.F.T. inlet v.v. Auto opening command at RFT [v] <-250 mm, Auto closing command at RFT [v] >+ 250 mm and Protection close command at RFT [v] > 850 mm

(from CWA/CWN panels)

4.4

Steam Turbine

Steam Turbine Protections 1) 2) 3) 4) 5) Turbine vacuum protection Condenser vacuum -0.7 bar(2/3 logic) (enable- turbine speed > 95) Lube oil pr. Lube oil pressure ,1.1 bar (2/3 logic) Shaft position prot. Turbine shaft displacement >+/- 1 mm (1/2 logic) Oil tank level prot. Oil tank level <-300 mm (2/3 logic) Gen. Prot. Main lead Level gen. main lead top >MAX (2/2 logic) 5) Gen. Prot. Cold gas CLd gas temp after cLr. A/B/C/D > 50 Deg C (2/2 LOGIC)

56

7)

HP Exh. Stm. Temp prot. HP inner casing 100% temp > 400 Deg C (2/2 logic)

8)

Wet steam prot. 1 (WHRHB 1) HP stm. Temp < 20 Deg.C less than saturation temperature (1/2 logic)

Enable HPCVI 0% HPCVI2 0% or lift set point turb. Contr. 0% 9) 10) wet steam prot. 2 (WHRB 2) WHRB 1 Trip & (M.S. Stop V/V WHRB 2 closed or BLr. Inlet dampers WHRB 2 closed WHRB 2 trip & (M.S. Stop V/V WHRB 1 closed or BLr. Inlet dampers WHRB 1 closed) man Turb. Trip 1 Man Trub. Trip 2 Man Trub. Trip 1 man Turb. Trip 2 Fire prot. PB 1 -do-do-do2 1 2 : : : : : : : : CWA pn. 1. - doCWN pn. 1 -doCWA pn. 1 - doCWN pn. 1 -do-

11)

12) 13) 14) 15) 16) 17) 18) 19) 20) 21)

Elect. Gen. prot 1 Elect. Gen. prot 2

Wet steam Temp. Prot. Variable set points

Pr. (kg/Sq. cm) 30 35 : :

Temp. (Deg. Set point) 239 246

57

40 45 50 55 60 65

: : : : : :

253 260 265 270 275 289

4.2.1 HP/LP Protections Trip initiating signals ______________________________________________________________________ S.NO. Description set value Remarks

______________________________________________________________________ I. II. III. Cond. Vacuum protection Water injection pr. Manual trip <-4.0 bar < 5.5 bar 2/3 logic 2/3 logic -

4.2.2 ST Auxillaries 1) Lube Oil pump Trip initiating signals:

58

Fire protection ch 1 Operated Fire Protection ch 2 operated ii) Emer. Oil Pump (DC)

Protection Start On lube Oil pressure <1.1 bar iii) Jacking Oil pump 1 Release for start of pump : JOP2 (DC) Off

I)

CO2 system :

Gas Turbine units

____________________________________________________________________ Area No of heat Detecters _____________________________________________________________________ i) Cumbustion chamber ii) iii) Lub oil tank Fuel oil inj. 4 Nos) 2Nos 190oF (88oC) 8 nos/c.c 325oF (163oC) - do- do 2 out of 2 logic Seting Remarks

Area Panels :

AP 1 to AP 7

No of Fire Monitorings modules 152 Features :Open, short & ground fault monitoring

Alarm indication through LEDs & Audio/ Visual annunciation in local & CCR Actuation & CO2 release on sensing fire initiation of GT Trip

CO2 Panels :No of CO2 actuator modules 16

59

Features

:-

Actuation of CO2 release on sensing fire after a time delay of 30 sec.

i) ii) iii) 2)

Audio/ Visual annunciation of CO2 release in Local/CCR Open & short fault monitoring .. Manual release of CO2 from local EPB without time delay Selector switches provided for Auto / Manual release of CO2 Main / Stand by CO2 cylinder CO2 release operation Isolate/ Inhabit from panel/ local. Halon system :

________________________________________________________________ Area No of I.S.D Detectors OSD

________________________________________________________________ GT containers Stack containers CCR/DAS room Fire Protection room Relay room Battery room Below false floor, Relay room Switchgear Room Static Ecitation Room ST1/ST2 8 8 15 23 15 23 3 22 3 22 56 20 51 56 20 51

Halon Panels No of Halon Actuator modules 30

60

Features :- Initiation of Halon release on sensing fire after time delay of 30 S (configured in 2 out of 2 logic) Manual release of Halon through local EPB without time delay

Selector switches Provided . i) ii) iii) Auto/ manual mode for halon release Isolate/ Inhabit mode for prevention of superious halon release. Main / Std by Halon cylinders.

4) Fire Detection & Alarms ____________________________________________________________________ Area No. of ISD Detectors OSB Remarks

____________________________________________________________________ - Black start DG room - Cable gallery 6 LHS cable is also provided - Fuel unloading station 16 nos ROR detectors are provided. - Module PP house - AC plant 36 14 -

Linear heat sensor cable for sensing fire in cable gallary provided For Auto/ Visual annunciation of fire local Repeater panels are provided.

4)

Central Fire Monitoring System Features 1) Display of Fire alarms and fault signals fo total plant area in CCR through microprocessor based system Monitor. ii) Hard copy print out of alarm & fault signals through printer.

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7.2

Air Compressor system

Mode of operatioin of compressors:

i) -

Continuous run

load un load regulation

Motor runs continuously Compressor gets unloaded by 50% at reciever Pr. > 8.4 Kg/Cm Sq. 100% at receiver Pr. > 8.7 Kg/Cm Sq. Compressor gets loaded by 50% at receiver Pr. < 8.2 Kg/Cm Sq. 100 % at receiver Pr. < 7.9 Kg/Cm Sq.

2)

Auto Start Stop regulation :Compressor starts automatically at air receiver Pr. < 7KG/Cm Sq.

Compressor gets unloaded at air receiver pr. < 7.8 Kg/cm2 remains unloaded, the motor stops. Compressor Protections _____________________________________________________________________ S.NO. Description set value

_____________________________________________________________________ 1. 2. 3. 4. 5. 6. 7. 8. 9. Lube Oil pressure low HP delivery volume Air Pressure separator 2 Kg/Cm Sq.(Time delay 15 sec.) 8.9 Kg/Cm Sq. 8.9 Kg/cm Sq.

Cooling water inlet flow very low 230 Lts/Min HP delivery volume bottle air temp. High Moisture separator air temp. high Compressor outlet cooling water temp. high Lube oil temp. high Motor over load 67oC 48oC 48oC 163oC

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Air Drying Plant Sequence of Operation

Step No time 1 2. ---1 min

Action SVI on (adsorber A i/s) SV1 Off SV4 On (depressurised B) SV2 ON\ (adsorber B i/s) SV2 Off SV4 on (Depressurised A) SV4 off SV3 on

3.

15 min

SV4 off SV3 on

Pre- selected blower (s) on Pre-selected blower (s) on 4. 5. 6. 16 min 4 hrs. 16 min. 5 hrs 16 min. (react. Ads B) Heaters off blowers off SV3 off 7. 8. 7 hrs. 45 min 8 hrs. SV5 on (Reacti. Ads A)

Heaters off blowers off SV3 off SV5 on (Repressurised A) SV5 off memory reset

(Repressurised B) SV5 off Memory reset

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7. Conclusion NTPC plays a very vital role in total power supply in our nation. It is one of the largest PSUs in our country. As a trainee, when I first went there I wasnt sure about what I will get to learn considering my branch of engineering. But, when I went there all my doubts were removed. It was a great experience working at NTPC with one of the finest engineers in our country. I got to learn a lot from them regarding the plant operation and maintenance. I learned about control systems and high speed data communication from plant sites to control room. Also, got to learn about management skills from department managers. We had interactive sessions with the engineers as well as labors working in the plant. This industrial visit helped me to familiarize with industrial environment. It helped me to visualize many of the concepts that were only available in theoretical form in books. Overall it was a great experience at NTPC.

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8. References
Device Manuals provided at NTPC http://www.ntpc.co.in http://www.wikipedia.com