A

SUMMER TRAINING
REPORT ON

CONTROL SCHEMES OF THERMAL POWER PLANT

SYSTEM
IN

BHARAT HEAVY ELECTRICAL LIMITED

PS –PEM, NOIDA

BACHELOR OF TECHNOLOGY
IN
ELECTRONICS & COMMUNICATION ENGINEERING

BY

NIKHIL KUMAR
AMBEDKAR INSTITUTE OF ADVANCED
COMMUNICATION TECHNOLOGIES &
RESEARCH , GGSIPU
 CERTIFICATE

This is to certify that the report entitled “CONTROL SCHEMES OF THERMAL POWER
PLANT SYSTEM” submitted by NIKHIL KUMAR, B.TECH (ELECTRONICS &
COMMUNICATION ENGINEERING) after completion of 7 weeks industrial training is a
bonafide student and work is carried out by here under my supervision and guidance. This
report is as a part of her training program and being submitted to C&I Department,
PEM, BHEL, NOIDA.

Ms. AANCHAL CHOUDHARY Mr. S.K GURUMUKHI

SENIOR ENGINEER DEPARTMENT HEAD

PEM (C&I) PEM (C&I)

BHEL, Noida BHEL, Noida

 ACKNOWLEDGEMENT
I hereby take this opportune moment to express my deep sense of gratitude to the Department Head
Mr. S.K GURUMUKHI (DH-C&I), for his unstinted support and encouragement to me. I express
my heartfelt thanks to Ms. AANCHAL CHOUDHARY (Senior Engineer) and for being a source
of guidance and inspiration for me during this period. Her wonderful style of mentoring has surely
made my training period a great learning experience. She always put in a sincere effort to make me
learn and devoted a lot of her valuable time to make sure that I receive proper modular training.

I also want to thank Mr. JIWAN SINGH who was always cooperative and helped me in every
possible manner during my internship period at PEM-(C&I), BHEL.I express my sincere thanks to
all the members of C&I Department for their friendly and helpful attitude.

DATE-12/07/2016 PRATEEKSHA MAHESHWARI

ZAKIR HUSSAIN COLLEGE OF ENGINEERING &

TECHNOLOGY,AMU
 TABLE OF CONTENTS
ABSTRACT

Chapter 1 OVERVIEW OF BHEL

BHEL – AN OVERVIEW

UNITS OF BHEL

Chapter 2 OVERVIEW OF PEM

PROJECT ENGINEERING MANAGEMENT DIVISION

Chapter 3 OVERVIEW OF C&I DEPARTMENT

C&I DEPARTMENT – AN OVERVIEW

Chapter 4 INTRODUCTION

ABOUT THERMAL POWER PLANT

PRINCIPLE OF THERMAL POWER PLANT—RANKINE CYCLE

ABOUT KKS NUMBERING SYSTEM

Chapter 5 MEASUREMENTS
LEVEL MEASUREMENT

FLOW MEASUREMENT

PRESSURE MEASUREMENT

TEMPERATURE MEASUREMENT

Chapter 6 UNDERSTANDING OF CONTROL SCHEMES

 BINARY CONTROL SCHEME

CONTROL SCHEMES OF DEMINERALISE COOLING WATER PUMP

  ANALOG CONTROL SCHEME

CONTROL SCHEMES OF HP BYPASS

CONCLUSION

REFERENCES
 CHAPTER 1

AN OVERVIEW OF BHEL

BHEL - AN OVERVIEW

BHEL is an integrated power plant equipment manufacturer and one of the largest engineering and
manufacturing companies in India in terms of turnover.

It was established in 1964, ushering in the indigenous Heavy Electrical Equipment industry in India.
The first plant of what is known as BHEL, was established more than 50 years ago at Bhopal (on
29.08.1956), and was the genesis of the Heavy Equipment Industry in India.

The company has been earning profits continuously since 1971-72 and paying dividends since 1976-
77.BHEL is engaged in the design, engineering, manufacture, construction, testing, commissioning
and servicing of a wide range of products and services for the core sectors of the economy, viz.
Power Transmission, Industry, Transportation, Renewable Energy, Oil & Gas and Defence.

BHEL’s operations are organized around three business sectors, namely:

  Power Sector
 Industry Sector
 International Operations

This enables BHEL to have a strong customer orientation, to be sensitive to his needs & to respond
quickly to the changes in the market.

The wide network of BHEL consists of:

 17 manufacturing divisions
 4 Power Sector Regional centers
 8 Service centers and
 15 Regional offices

4 PS regions and corresponding service centers are:

 PS-NR Noida,
 PS-SR Secunderabad
 PS-ER Kolkata, Patna
  PS-WR Nagpur, Vadodra

Such wide network of BHEL enables the Company to promptly serve its customers and provide them
with suitable products, systems and services - efficiently and at competitive prices. The high level of
quality & reliability of its products is due to the emphasis on design, engineering and manufacturing
to international standards by acquiring and adopting some of the best technologies from leading
companies in the world, together with technologies developed in its own R&D centers. Having
attained ISO 9000 certification, BHEL is now well on its journey towards Total Quality Management
(TQM). On the Environmental Management front the major units of BHEL have already acquired
the ISO 14001 certification.
The greatest strength of BHEL is its highly skilled & committed employees. Every employee is
given an equal opportunity to develop himself & improve his position. Continuous training &
retraining, career planning, a positive work culture & participative style of management have
engendered development of a committed & motivated work force leading to enhanced productivity
& higher levels of quality.

UNITS OF BHEL

UNIT PERIOD PRODUCTS

BHOPAL ESTABLISHED – 1. THERMAL SETS (30/120/210 MW)

1956 2. MARINE TURBINES
(HEP) PRODUCTION 3. NUCLEAR TURBINES (UPTO 235 MW)
4. HYDRO SETS (5 MW TO 200 MW)
STARTED-1960
5. POWER TRANSFORMER UPTO 0-400 KV
6. SWITCHGEAR (BULK OIL, MOCB, SF6)
7. HEAT EXCHANGERS
8. CAPACITORS, RECTIFIERSAND
THYRISTOR CONVERTORS
9. TRACTION SYSTEMS
10. AVR & STATIC EXCITATION
HARIDWAR ESTABLISHED- 1. THERMAL SETS (210/250/500 MW)
1963 2. GAS TURBINE SETS
(HEEP) PRODUCTION 3. NUCLEAR SETS (235/500 MW)
4. HYDRO SETS
STARTED-1967
5. AC/DC MOTORS
HYDRABAD ESTABLISHED- 1. THERMAL SETS (60/110 MW)
1963 2. BOWL MILLS
(HPEP) PRODUCTION 3. SYNCHRONOUS CONDENSERS
 STARTED-1965 4. INDUSTRIAL TURBO SETS
5. PUMPS
6. OIL RIGS
7. HEAT EXCHANGERS
8. GAS TURBINES
TRICHY ESTABLISHED- 1. BOILERS
(HPBP) 1963 2. BOILERS AUXILIARIES
PRODUCTION 3. INDUSTRIAL BOILERS
STARTED-1965 4. VALVES
HARIDWAR ESTABLISHED- 1. CI CASTINGS 12000 MT
1974 2. NF CASTINGS 250MT
(CFFP) PRODUCTION 3. STEEL CASTINGS 6000MT
4. FORGINGS 3250 MT
STRARTED-1976
5. BILLETS & BLOOMS 4000MT
6. INGOTS 10000 MT
7. HOT DIE STEEL
JHANSI PRODUCTION 1. POWER AND OTHER TRANSFORMERS
STARTED-1976 (UPTO 220 KV)
(TP) 2. RECTIFORMERS
3. FREIGHT
4. LT SWITCHGEARS

TRICHY ESTABLISHED- 1. SEAMLESS STEEL TUBES

1976
(SSTP) PRODUCTION
STARTED-1979
BANGALORE ESTABLISHED- 1. ENERGY METERS, WATER METERS
1976 2. PLANT ELECTRONICS
(EDN) REMCO (MERGED 3. POWER DEVICES
4. THYRISTOR CONVERTORS
WITH BHEL) -1980
BANGALORE SET UP-1932 1. DISC INSULATORS
REMCO (MERGED 2. LINE HARDWARE
(EPD)
WITH BHEL) -1980 3. BUS HINGS
4. SOLID CORE INSULATORS
JAGDISHPUR 1. FABRICATION ASSEMBLIES

(FP)

RANIPET ESTABLISHED- 1. FANS

1976 2. ELECTROSTATIC PRECIPITATORS
(BAP) REMCO (MERGED 3. AIR PREHEATERS
WITH BHEL) -1980
 GOINDWAL ESTABLISHED- 1. GATE VALVES
1983
(IVP) PRODUCTION
STARTED-1984
JAGDISHPUR PRODUCTION 1. HIGH TENSION CERAMIC INSULATORS
STARTED-1984 2. REPAIR SHOP (CAN BE ENGAGED FOR
(IP) PRODUCTION OF CRITICAL SPARES)

VARANSI

(HERP)

RUDRAPUR PRODUCTION 1. SOLAR WATER HEATING SYSTEMS

STARTED-1984 2. SOLAR LANTERN
(CFP) 3. BUSDUCTS

JAGDISHPUR 1. STAMPINGS FOR ELECTRICAL

MACHINES
(CSU)

THIRUMAYAM 1. PIPING SYSTEMS FOR THERMAL

POWER PLANTS
(PPPU) 2. STEAM PIPING LINES FOR NUCLEAR
POWER PLANTS AND PIPING SYSTEMS
FOR PROCESS INDUSTRIES

VIZAG 1. BOILER AND PRESSURE VESSELS

(HPVP)
 CHAPTER 2

OVERVIEW OF PEM

PROJECT ENGINEERING MANAGEMENT DIVISION

BHEL PEM business in the field of power generation equipment, which is handled by the Power
Group, covers all the services related to power projects from concept to commissioning.

PEM coordinates with all the agencies involved in the setting up of the power plant and smoothly
integrates all the requirements of manufacturing, fabrication, erection, commissioning, operations
and maintenance, right at the engineering and design stage.
EVOLUTION OF PEM

 BHEL’s power plant “system integrator”

 Setup in 1974 – then known as “Consultancy Services Division” (CSD) to address the market
demand for turnkey services in power and related areas.
 In 1977, CSD was renamed as “Project Engineering Division” (PED).
 In 1984, was renamed as “Project Engineering Management” (PEM) as it is currently known.

DEPARTMENTS IN PEM

Departments of PEM can be broadly divided under following heads based on different functions:
 Engineering Functions
 Operations Functions
 Support Functions

There are six engineering based departments:

 Control and Instrumentation Department
 Civil Department
 Electrical Department
 Mechanical Auxiliaries Department
 Mechanical Piping and Layout Department
 Mechanical Systems Engineering Department

Along with these above mentioned engineering departments, PEM has other important departments:
 Project Group I , II , III
 CMM Department
 Quality Department
 Information Technology Department
 Finance department
 Proposal Engineering Department
 Human Resource Department
  Vendor Development (VD)
 MSX & Planning
 PPDC (Power Plant Development Cell)
 IPDS

PEM is a resource pool of talented professionals with state of the art infrastructure and management
practices. It has:
 Capability to handle projects on turnkey / EPC basis
 Wide range of engineering capabilities
 Capability to design to national and international codes and standards - BS, DN, ASME, API,
IBR, EJMA, IEC, VDE, IEEE
 Varied experience with national and international consultants
 Pool of experienced human resources
 Experience of over 200 coal based and gas based power stations
 Over 550 qualified and registered vendors / sub-contractors
 Engineering and Design office with adequate modeling, analysis and design software
 State-of-the-art IT infrastructure of servers, engineering workstations, LAN, high bandwidth
external connectivity for e-mail, internet and data transfer.
 CHAPTER 3
OVERVIEW OF C&I DEPARTMENT
C&I DEPARTMENT- AN OVERVIEW

Control and Instrumentation in any process industry, can be compared to the nerve system in the
human being. The way the nerve system controls the operation of various limbs of human being,
C&I in the same way controls the various motors, pumps, dampers, valves etc., which in turn helps
us to control the process.

Automation and control being areas with fast changes and rapid progress, this is a very dynamic and
an incessantly growing area. Hence, it becomes very essential for every C&I engineer to keep abreast
of latest technological advancements and developments going on internationally.

The Control and Instrumentation Department looks after project engineering & application software
for Control & Instrumentation packages for Thermal and Combined cycle power plants, comprising
of the following sub-systems-

 Control room engineering

 Latest state-of-the-art Distributed Digital Control Monitoring and Information System
(DDCMIS)
 Engineering of field instrumentation
 Engineering for control elements like control valves, power cylinders, actuators etc.
and flow elements.
 Protection and interlocks
 Alarm annunciation system
 Uninterrupted power supply system
 Open and close loop controls
 Steam and water analysis and pollution monitoring system
 Supervisory, analytical, and laboratory instruments
 Control and instrumentation for various mechanical auxiliary systems
The Control and Instrumentation is inherent to boiler, turbine and generator. The manufacturing
plants of the individual equipments take care of the boiler integral and TG integral C&I. PEM-C&I
take care of the regenerative cycle i.e. the system in between the condenser and the boiler,
comprising of various heat exchangers and rotating equipments (BFP, CEP etc.). Apart from this, the
closed loop control of the boiler area and interlock & protection of the boiler auxiliaries (ID, FD, PA
& AH) is also within the purview of PEM C&I.

The C&I engineering for the balance of plant equipment like- Ash Handling Plant, DM Plant,
Compressed Air System, Water System, AC & Ventilation etc. is also the responsibility of PEM-
C&I. As mentioned above PEM-C&I is a project-engineering agency that unifies the C&I of an
entire power plant.

FUNCTIONS OF C&I DEPARTMENT

The major functions of Control and Instrumentation Department are:

 Proposal Engineering
 Contract Engineering
 Provide support services for Auxiliary plants
 Standardization
 CHAPTER 4

INTRODUCTION
ABOUT THERMAL POWER PLANT
The greatest variation in the design of thermal power stations is due to the different fossil fuel
resources generally used to heat the water. Some prefer to use the term energy center because such
facilities convert forms of heat energy into electrical energy. Certain thermal power plants also are
designed to produce heat energy for industrial purposes of district heating, or desalination of water,
in addition to generating electrical power. Globally, fossil fueled thermal power plants produce a
large part of man-made CO2 emissions to the atmosphere, and efforts to reduce these are varied and
widespread.

Electricity is the only form of energy that is easy to produce, transport, use and control. So it is
generally the terminal form of energy used for transmission and distribution. Electricity cannot be
stored and must be used immediately.

Electricity consumption per capita is the index of the living standard of people.

Electricity in bulk quantity is produced in power plants which can be of following types-

(a) Thermal- The working fluid is steam. They use fossil fuels – coal, natural gas or fuel oil as
energy source. Thus they are of three types-
 Coal based
 Gas based
 Fuel oil based
(b) Nuclear- Uses nuclear reactor as heat source and steam as the working fluid. This type of
plant is facing huge opposition due to potential dangerous effects of nuclear fuel.
(c) Hydraulic- This plant also uses steam as the working fluid. They are used for multiple
purposes of generating electricity, irrigation, flood control, fisheries, afforestation, navigation
etc. They are however expensive and take long time to build. They are facing opposition due
to ecological imbalance they cause.
(d) Gas turbine- They are often used as peaking units, and run for short periods to meet the
peaking demands of load. They are however increasingly being used in conjugation with a
bottoming steam plant in combined cycle power generation mode.
(e) Others-
 Wind- Wind turbines can be used to generate electricity in areas with strong, steady
winds, sometimes offshore.
 Solar- Solar energy can be turned into electricity either directly in solar cells, or in
a concentrating solar power plant by focusing the light to run a heat engine.
 Geothermal- They can be build in only certain geographical locations.
 Biomass plants
At present 54.09% or 93918.38 MW of total electricity production in India is from Coal Based
Thermal Power Station. A coal based thermal power plant converts the chemical energy of the coal
into electrical energy. This is achieved by raising the steam in the boilers, expanding it through the
turbine and coupling the turbines to the generators which converts mechanical energy into electrical
energy.

Fig. Power Production

GT – GAS TURBINE
UAT – UNIT AUXILLARY TRANSFORMERS
PRINCIPLE OF THERMAL POWER PLANT

A thermal power plant is a power plant in which the prime mover is steam driven. Water is heated,
turns into steam and spins a steam turbine which drives an electrical generator. After it passes
through the turbine, the steam is condensed in a condenser and recycled to where it was heated; this
is known as a Rankine cycle.

Thermal power plants use water as working fluid. In a thermal power plant a steam turbine is rotated
with help of high pressure and high temperature steam and this rotation is transferred to a generator
to produce electricity.

Working
In a coal based power plant coal is transported from coal mines to the power plant by railway in
wagons. Coal is unloaded from the wagons to a moving underground conveyor belt. This coal from
the mines is of no uniform size. So it is taken to the Crusher house and crushed to a size of 20mm.
The Coal Mills pulverizes the coal. The powdered coal from the coal mills is carried to the boiler in
coal pipes by high pressure hot air. The pulverized coal air mixture is burnt in the boiler in the
combustion zone.

Generally in modern boilers tangential firing system is used i.e. the coal nozzles/ guns form tangent
to a circle. The temperature in fire ball is of the order of 1300 degree Celsius. The boiler is a water
tube boiler hanging from the top. Water is converted to steam in the boiler and steam is separated
from water in the boiler Drum. The saturated steam from the boiler drum is taken to the Low
Temperature Superheater, Platen Superheater and Final Superheater respectively for superheating.
The superheated steam from the final superheater is taken to the High Pressure Steam Turbine
(HPT). In the HPT the steam pressure is utilized to rotate the turbine and the resultant is rotational
energy. From the HPT the out coming steam is taken to the Reheater in the boiler to increase its
temperature as the steam becomes wet at the HPT outlet. After reheating this steam is taken to the
Intermediate Pressure Turbine (IPT) and then to the Low Pressure Turbine (LPT), the outlet of the
LPT is sent to the condenser for condensing back to water by a cooling water system. This
condensed water is collected in the hot well and is again sent to the boiler in a closed cycle. The
rotational energy imparted to the turbine by high pressure steam is converted to electrical energy in
the Generator.
Efficiency

The energy efficiency of a conventional thermal power station, considered energy produced as a
percent of the heating value of the fuel consumed, is typically 33% to 48% As with all heat engines,
their efficiency is limited, and governed by the laws of thermodynamics. By comparison, most
hydropower stations in the United States are about 90 percent efficient in converting the energy of
falling water into electricity.

The energy of a thermal not utilized in power production must leave the plant in the form of heat to
the environment. This waste heat can go through a condenser and be disposed of with cooling water
or in cooling towers. If the waste heat is instead utilized for district heating, it is called co-generation.

An important class of thermal power station is associated with desalination facilities; these are
typically found in desert countries with large supplies of natural gas and in these plants, freshwater
production and electricity are equally important co-products.

The Carnot efficiency dictates that higher efficiencies can be attained by increasing the temperature
of the steam.

Sub-critical fossil fuel power plants can achieve 36–40% efficiency.

Super critical designs have efficiencies in the low to mid 40% range, with new "ultra critical" designs
using pressures of 4400 psi (30.3 MPa) and multiple stage reheat reaching about 48% efficiency.
Above the critical point for water of 705 °F (374 °C) and 3212 psi (22.06 MPa), there is no phase
transition from water to steam, but only a gradual decrease in density.

Currently most of the nuclear power plants must operate below the temperatures and pressures that
coal-fired plants do, since the pressurized vessel is very large and contains the entire bundle of
nuclear fuel rods. The size of the reactor limits the pressure that can be reached. This, in turn, limits
their thermodynamic efficiency to 30–32%. Some advanced reactor designs being studied, such as
the very high temperature reactor, advanced gas-cooled reactor and supercritical water reactor, would
operate at temperatures and pressures similar to current coal plants, producing comparable
thermodynamic efficiency.

Electricity Cost
The direct cost of electric energy produced by a thermal power station is the result of cost of fuel,
capital cost for the plant, operator labor, maintenance, and such factors as ash handling and disposal.
Indirect, social or environmental costs such as the economic value of environmental impacts, or
environmental and health effects of the complete fuel cycle and plant decommissioning, are not
usually assigned to generation costs for thermal stations in utility practice, but may form part of an
environmental impact assessment.

COMPONENTS OF COAL FIRED THERMAL POWER PLANT

Main parts of the plant are:

1. Coal conveyor: This is a belt type of arrangement. With this coal is transported from coal storage
place in power plant to the place nearby boiler.

2. Stoker: The coal which is brought nearby boiler has to put in boiler furnace for combustion. This
stoker is a mechanical device for feeding coal to a furnace.

3. Pulverizer: The coal is put in the boiler after pulverization. For this pulverizer is used. A
pulverizer is a device for grinding coal for combustion in a furnace in a power plant.

4. Boiler: Now that pulverized coal is put in boiler furnace. Boiler is an enclosed vessel in which
water is heated and circulated until the water is turned in to steam at the required pressure.

Coal is burned inside the combustion chamber of boiler. The products of combustion are nothing but
gases. These gases which are at high temperature vaporize the water inside the boiler to steam.
Sometimes this steam is further heated in a superheater as higher the steam pressure and temperature
the greater efficiency the engine will have in converting the heat in steam in to mechanical work.
This steam at high pressure and temperature is used directly as a heating medium, or as the working
fluid in a prime mover to convert thermal energy to mechanical work, which in turn may be
converted to electrical energy. Although other fluids are sometimes used for these purposes, water is
by far the most common because of its economy and suitable thermodynamic characteristics.

Classification of Boilers
Boilers are classified as

Fire tube boilers: In fire tube boilers hot gases are passed through the tubes and water surrounds
these tubes. These are simple, compact and rugged in construction. Depending on whether the tubes
are vertical or horizontal these are further classified as vertical and horizontal tube boilers. In this
since the water volume is more, circulation will be poor. So they can't meet quickly the changes in
steam demand. High pressures of steam are not possible, maximum pressure that can be attained is
about 17.5kg/sq. cm. Due to large quantity of water in the drain it requires more time for steam
raising. The steam attained is generally wet, economical for low pressures. The output of the boiler is
also limited.

Water tube boilers: In these boilers water is inside the tubes and hot gases are outside the tubes. They
consist of drums and tubes. They may contain any number of drums. Feed water enters the boiler to
one drum (here it is drum below the boiler).This water circulates through the tubes connected
external to drums. Hot gases which surround these tubes will convert the water in tubes in to steam.
This steam is passed through tubes and collected at the top of the drum since it is of light weight. So
the drums store steam and water (upper drum).The entire steam is collected in one drum and it is
taken out from there. As the movement of water in the water tubes is high, so rate of heat transfer
also becomes high resulting in greater efficiency. They produce high pressure, easily accessible and
can respond quickly to changes in steam demand. These are also classified as vertical, horizontal and
inclined tube depending on the arrangement of the tubes. These are of less weight and less liable to
explosion. Large heating surfaces can be obtained by use of large number of tubes.

Superheater: Most of the modern boilers are having superheater and reheater arrangement.
Superheater is a component of a steam-generating unit in which steam, after it has left the boiler
drum, is heated above its saturation temperature. The amount of superheat added to the steam is
influenced by the location, arrangement, and amount of superheater surface installed, as well as the
rating of the boiler. The superheater may consist of one or more stages of tube banks arranged to
effectively transfer heat from the products of combustion. Superheaters are classified as convection,
radiant or combination of these.

Reheater: Some of the heat of superheated steam is used to rotate the turbine where it loses some of
its energy. Reheater is also steam boiler component in which heat is added to this intermediate-
pressure steam, which has given up some of its energy in expansion through the high-pressure
turbine. The steam after reheating is used to rotate the second steam turbine (see Layout fig) where
the heat is converted to mechanical energy. This mechanical energy is used to run the alternator,
which is coupled to turbine, there by generating electrical energy.
5. Condenser: Steam after rotating steam turbine comes to condenser. Condenser refers here to the
shell and tube heat exchanger (or surface condenser) installed at the outlet of every steam turbine in
Thermal power stations of utility companies generally. These condensers are heat exchangers which
convert steam from its gaseous to its liquid state, also known as phase transition. In so doing, the
latent heat of steam is given out inside the condenser. Where water is in short supply an air cooled
condenser is often used. An air cooled condenser is however significantly more expensive and
cannot achieve as low a steam turbine backpressure (and therefore less efficient) as a surface
condenser.

The purpose is to condense the outlet (or exhaust) steam from steam turbine to obtain maximum
efficiency and also to get the condensed steam in the form of pure water, otherwise known as
condensate, back to steam generator or (boiler) as boiler feed water.

Why it is required?
The steam turbine itself is a device to convert the heat in steam to mechanical power. The difference
between the heat of steam per unit weight at the inlet to turbine and the heat of steam per unit weight
at the outlet to turbine represents the heat given out (or heat drop) in the steam turbine which is
converted to mechanical power. The heat drop per unit weight of steam is also measured by the word
enthalpy drop. Therefore the more the conversion of heat per pound (or kilogram) of steam to
mechanical power in the turbine, the better is its performance or otherwise known as efficiency. By
condensing the exhaust steam of turbine, the exhaust pressure is brought down below atmospheric
pressure from above atmospheric pressure, increasing the steam pressure drop between inlet and
exhaust of steam turbine. This further reduction in exhaust pressure gives out more heat per unit
weight of steam input to the steam turbine, for conversion to mechanical power. Most of the heat
liberated due to condensing, i.e., latent heat of steam, is carried away by the cooling medium. (water
inside tubes in a surface condenser, or droplets in a spray condenser (Heller system) or air around
tubes in an air-cooled condenser).

Condensers are classified as (i) Jet condensers or contact condensers (ii) Surface condensers.
In jet condensers the steam to be condensed mixes with the cooling water and the temperature of the
condensate and the cooling water is same when leaving the condenser; and the condensate can't be
recovered for use as feed water to the boiler; heat transfer is by direct conduction.

In surface condensers there is no direct contact between the steam to be condensed and the
circulating cooling water. There is a wall interposed between them through heat must be
convectively transferred. The temperature of the condensate may be higher than the temperature of
the cooling water at outlet and the condensate is recovered as feed water to the boiler. Both the
cooling water and the condensate are separately with drawn. Because of this advantage surface
condensers are used in thermal power plants.

6. Cooling Towers: The condensate (water) formed in the condenser after condensation is initially at
high temperature. This hot water is passed to cooling towers. It is a tower- or building-like device in
which atmospheric air (the heat receiver) circulates in direct or indirect contact with warmer water
(the heat source) and the water is thereby cooled (see illustration). A cooling tower may serve as the
heat sink in a conventional thermodynamic process, such as refrigeration or steam power generation,
and when it is convenient or desirable to make final heat rejection to atmospheric air. Water, acting
as the heat-transfer fluid, gives up heat to atmospheric air, and thus cooled, is recirculated through
the system, affording economical operation of the process.
The cooling towers are of four types: -
1. Natural Draft cooling tower
2. Forced Draft cooling tower
3. Induced Draft cooling tower
4. Balanced Draft cooling tower

7. Fan or draught system: In a boiler it is essential to supply a controlled amount of air to the
furnace for effective combustion of fuel and to evacuate hot gases formed in the furnace through the
various heat transfer area of the boiler. This can be done by using a chimney or mechanical device
such as fans which acts as pump.

i) Natural draught

When the required flow of air and flue gas through a boiler can be obtained by the stack
(chimney) alone, the system is called natural draught. When the gas within the stack is hot, its
specific weight will be less than the cool air outside; therefore the unit pressure at the base of
stack resulting from weight of the column of hot gas within the stack will be less than the
column of extreme cool air. The difference in the pressure will cause a flow of gas through
opening in base of stack. Also the chimney is form of nozzle, so the pressure at top is very
small and gases flow from high pressure to low pressure at the top.

ii) Mechanized draught

There are 3 types of mechanized draught systems

1) Forced draught system
2) Induced draught system
3) Balanced draught system
Forced draught: – In this system a fan called Forced draught fan is installed at the inlet of the
boiler. This fan forces the atmospheric air through the boiler furnace and pushes out the hot
gases from the furnace through superheater, reheater, economiser and air heater to stacks.
Induced draught: – Here a fan called ID fan is provided at the outlet of boiler, that is, just
before the chimney. This fan sucks hot gases from the furnace through the superheaters,
economiser, reheater and discharges gas into the chimney. This results in the furnace pressure
lower than atmosphere and affects the flow of air from outside to the furnace.
Balanced draught:-In this system both FD fan and ID fan are provided. The FD fan is utilized
to draw control quantity of air from atmosphere and force the same into furnace. The ID fan
sucks the product of combustion from furnace and discharges into chimney. The point where
draught is zero is called balancing point.
8. Economiser: Flue gases coming out of the boiler carry lot of heat. Function of economiser is to
recover some of the heat from the heat carried away in the flue gases up the chimney and utilize for
heating the feed water to the boiler. It is placed in the passage of flue gases in between the exit from
the boiler and the entry to the chimney. The use of economiser results in saving in coal consumption,
increase in steaming rate and high boiler efficiency but needs extra investment and increase in
maintenance costs and floor area required for the plant. This is used in all modern plants. In this a
large number of small diameter thin walled tubes are placed between two headers. Feed water enters
the tube through one header and leaves through the other. The flue gases flow outside the tubes
usually in counter flow.
9. Air preheater: The remaining heat of flue gases is utilized by air preheater. It is a device used in
steam boilers to transfer heat from the flue gases to the combustion air before the air enters the
furnace. Also known as air heater; air-heating system. It is not shown in the lay out. But it is kept at a
place nearby where the air enters in to the boiler. The purpose of the air preheater is to recover the
heat from the flue gas from the boiler to improve boiler efficiency by burning warm air which
increases combustion efficiency, and reducing useful heat lost from the flue. As a consequence, the
gases are also sent to the chimney or stack at a lower temperature, allowing simplified design of the
ducting and stack. It also allows control over the temperature of gases leaving the stack (to meet
emissions regulations, for example).After extracting heat flue gases are passed to electrostatic
precipitator.
10. Electrostatic precipitator: It is a device which removes dust or other finely divided particles
from flue gases by charging the particles inductively with an electric field, then attracting them to
highly charged collector plates ( Also known as precipitator). The process depends on two steps. In
the first step the suspension passes through an electric discharge (corona discharge) area where
ionization of the gas occurs. The ions produced collide with the suspended particles and confer on
them an electric charge. The charged particles drift toward an electrode of opposite sign and are
deposited on the electrode where their electric charge is neutralized. The phenomenon would be
more correctly designated as electro deposition from the gas phase.
The use of electrostatic precipitators has become common in numerous
industrial applications. Among the advantages of the electrostatic precipitator are its ability to handle
large volumes of gas, at elevated temperatures if necessary, with a reasonably small pressure drop,
and the removal of particles in the micrometer range. Some of the usual applications are: (1) removal
of dirt from flue gases in steam plants; (2) cleaning of air to remove fungi and bacteria in
establishments producing antibiotics and other drugs, and in operating rooms; (3) cleaning of air in
ventilation and air conditioning systems; (4) removal of oil mists in machine shops and acid mists in
chemical process plants; (5) cleaning of blast furnace gases; (6) recovery of valuable materials such
as oxides of copper, lead, and tin; and (7) separation of futile from zirconium sand.

11. Smoke stack: A chimney is a system for venting hot flue gases or smoke from a boiler, stove,
furnace or fireplace to the outside atmosphere. They are typically almost vertical to ensure that the
hot gases flow smoothly, drawing air into the combustion through the chimney effect (also known as
the stack effect). The space inside a chimney is called a flue. Chimneys may be found in buildings,
steam locomotives and ships. In the US, the term smokestack (colloquially, stack) is also used when
referring to locomotive chimneys. The term funnel is generally used for ship chimneys and
sometimes used to refer to locomotive chimneys. Chimneys are tall to increase their draw of air for
combustion and to disperse pollutants in the flue gases over a greater area so as to reduce the
pollutant concentrations in compliance with regulatory or other limits.
12. Generator: An alternator is an electromechanical device that converts mechanical energy to
alternating current electrical energy. Most alternators use a rotating magnetic field. Different
geometries - such as a linear alternator for use with engines - are also occasionally used. In principle,
any AC generator can be called an alternator, but usually the word refers to small rotating machines
driven by automotive and other internal combustion engines.

13. Transformers: It is a device that transfers electric energy from one alternating-current circuit to
one or more other circuits, either increasing (stepping up) or reducing (stepping down) the voltage.
Uses for transformers include reducing the line voltage to operate low-voltage devices (doorbells or
toy electric trains) and raising the voltage from electric generators so that electric power can be
transmitted over long distances. Transformers act through electromagnetic induction; current in the
primary coil induces current in the secondary coil. The secondary voltage is calculated by
multiplying the primary voltage by the ratio of the number of turns in the secondary coil to that in the
primary.

Advantages of coal based thermal Power Plant

 They can respond to rapidly changing loads without difficulty.

 A portion of the steam generated can be used as a process steam in
different industries
 Steam engines and turbines can work under 25 % of overload
continuously
 Fuel used is cheaper
 Cheaper in production cost in comparison with that of diesel power
stations
 Economical for low initial cost other than any generating plant.
 Land required less than hydro power plant.
 Since coal is main fuel & its cost is quite cheap than petrol/diesel so
generation cost is economical.
 It has easier maintenance.
 Thermal power plant can be installed in any location where
transportation & bulk of water are available

Disadvantages of coal based thermal Power Plant

 Maintenance and operating costs are high

 Long time required for erection and putting into action
 A large quantity of water is required
 Great difficulty experienced in coal handling
 Presence of troubles due to smoke and heat in the plant
 Unavailability of good quality coal
 Maximum of heat energy lost
 Problem of ash removing
 The running cost for a thermal power station is comparatively high due
to fuel, maintenance etc.
 Large amount of smoke causes air pollution. The thermal power station
is responsible for Global warming.
 The heated water that comes from thermal power plant has an adverse
effect on the lives in the water and disturbs the ecology.
 Overall efficiency of thermal power plant is low like less 30%.
KKS NUMBERING SYSTEM
The Planner and Operators of Power Station requires a common, standard system for identifying
installation, and part thereafter, with which the data required to Plan, Construct and Operate Power
Stations can be collected and processed. It is absolutely essential for the agencies participating in the
construction and operation of a Power Plant to agree upon a standard system for the designation and
classification of the plant; its part and components. Due to the size of Power Plants and the fact that
the number of agencies participating are all in different location, communication problem arise
which can incur costs.
KKS designation system for Power Plant enables various agencies,
irrespective of language and assignment, to identify/name uniformly and unambiguously respective
part/portions of the plant within their responsibility.
The identification system for Power Station “KKS” serves to identify plants, section of plant
and items of equipments in any type of power station according to task, type and location. In Consideration of
various requirement of plant coding, KKS consists of three type of designation: a)
Process Related designation identifies installation and equipment according to their assigned task in
the Power Plant. b) Location designation
identifies the points of installation within a sub system. c) Room Designation identifies the
room and floors or other installation sites for installations and equipment in building structures.
The
identification system for power stations “KKS” (Kraftwerk-Kennzeichen system) serves to identify
plants, section of plants and items of equipments in any type of power station according to task, type
and location. The code is made up of 3 to 4 breakdown levels. Each individual breakdown level is
formatted differently using alpha and numeric data characters.
• In all, the code is made up of maximum 17
data characters • the titles of the breakdown levels of the three types of
codes are as follows:

DESIGN PHILOSOPHY
Breakdown Level 0 1 2
Designation A N A A A N N A A N N N A
Example B L A C 1 0 C T 0 0 1 A
Sub Sys no.
Sub System

Circuit No.
Measuring
Circuit
UNIT
Unit Level Designation
It may be necessary to identify several units, unit-free plants or expansion stages within a power
station, such that a clear and unambiguous distinction exists between them. In such a case, this
designation must be agreed upon by all agencies concerned. It is recommended that an alphabetical
symbol be used here, since the next character F0 (prefix number) is numerical. The breakdown level
“OVERALL PLANT” can be omitted when the designation used in the power plant is otherwise
unambiguous.

Sub System Level Designation

If in the overall plant two or more identical subsystems are to be identified (2 boiler plants, 2 turbine
sets, 2 nuclear heat-generating systems) the prefix number is used to distinguish between them. Each
prefix number is valid only in the area of the function concerned. The alphabetical symbols of this
breakdown level are used to classify and divide the overall plant into subsystems, systems or
building structures. Wherever possible, all three alphabetical symbols are permanently allocated,
including their associated boundary constraints and task allotment in modern power plant
technology. The breakdown of the first alphabetical character of the function code is given as an
example:

Sub systems

A: Grid and Distribution systems

B: Power Transmission and Auxiliary Power Supply
C: Instrumentation and Control Systems (I&C)
E: Conventional Fuel Supply and Residue Disposal Equipment
F: Handling of Nuclear Equipment
G: Water Supply and Discharge
H: Conventional Heat Generation
J: Nuclear Heat Generation
K: Auxiliary Reactor Systems
L: Steam, Water and Gas Cycles
M: Main Machine Sets
N: Process Energy Distribution (external)
P: Cooling Water Systems
Q: Auxiliary Systems
S: Ancillary Systems
U: Structures
X: Large Machines (not including main machines)
Z: Operating and Office Equipment
 Measuring Circuit Level Designation
In process related designation the two alphabetical symbols are used to distinguish between the
mechanical apparatus & equipment units, Electrical and C&I equipment, and between the
measuring and closed loop control circuits.

Equipment Units:

A: Equipment Unit
B: Apparatus
C: Measuring Circuit
D: Closed Loop Control Circuits
E: Signal Processing
G: Electrical Equipment
H: Subassemblies of main and large machines
J: Nuclear Equipments

Example:

L is for Steam, Water, Gas Cycle

LA is for Feed Water System

LAC is for Boiler Feed Pump

i) Main Pump : LAC10AP

ii) Hydro. Coupling : LAC10AU

iii) Motor : LAC10AE

iv) Booster Pump : LAC10AP

v) Main Pump : LAC10AP

vi) Main Pump : LAC10AP

vii) Hydr. Coupling : LAC10AU

viii) Motor : LAC10AE

ix) Booster Pump : LAC10AP

Sub System Level Number Designation:

Use of numerical keys available in system code & equipment code with break down levels:
Use 10, 20, 30… to distinguish between main systems having same Alpha Codes. Examples:

a) Main Steam (Left) and Main Steam (Right)

b) BFP – A/B/C

c) ID Fan – A/B, FD Fan A/B, AH – A/B

For branch off from main system path, if it bears the same alpha code, use 11, 12, 13… 21, 22, 23
……. Etc.

If the branch off from main system / sub system path is used for some other system, where different
alpha codes can be applied, then in that case the said branch line will be designated by the alpha
codes of the system to which it is providing the input.
 CHAPTER 5
MEASUREMENT

The various measurement techniques are classified as:

1. Level Measurement

2. Flow Measurement

3. Pressure Measurement

4. Temperature Measurement

 LEVEL MEASUREMENT

There are multiple technologies available in the market to measure level. One of the important
methods/principles for level measurement is Differential Pressure.

Differential Pressure

Perhaps the most frequently used device for the measurement of level is a differential pressure
transmitter. Using DP for level is really an inferential measurement. A DP is used to transmit the
head pressure that the diaphragm senses due to the height of the material in the vessel multiplied
by a density variable.

P = ρ*g* h; where P=pressure, ρ=density,

G= acc. due to gravity, h= height

 FLOW MEASUREMENT

Flow measurement is the quantification of bulk fluid movement. Flow can be measured in a
variety of ways. The most common types of flow meters discussed are:

 ORIFICE PLATES
 FLOW NOZZLES
 ANNUBAR
 VARIABLE AREA ROTAMETERS
ORIFICE PLATES

An orifice plate is a device used for measuring flow rate, for reducing pressure or for restricting flow
(in the latter two cases it is often called a restriction plate). Either a volumetric or mass flow rate
may be determined, depending on the calculation associated with the orifice plate. It uses the same
principle as a Venturi nozzle, namely Bernoulli’s principle which states that there is a relationship
between the pressure of the fluid and the velocity of the fluid. When the velocity increases, the
pressure decreases and vice versa.

Advantages:

 Inexpensive and accurate.

 Measures a wide range of flow rates.

Disadvantages:

 Requires homogenous fluids.

 Causes a pressure drop in fluids.

FLOW NOZZLES

A nozzle is a device designed to control the direction or characteristics of a fluid flow (especially to
increase velocity) as it exits (or enters) an enclosed chamber or pipe. A nozzle is often a pipe or tube
of varying cross sectional area and it can be used to direct or modify the flow of a fluid (liquid or
gas). Nozzles are frequently used to control the rate of flow, speed, direction, mass, shape, and/or the
pressure of the stream that emerges from them.
 Fig. Flow Nozzle

Advantages:
 Easy installation and cheap
 Compact and high coefficient of discharge

Disadvantages:
 Low pressure recovery
 High maintenance

ANNUBAR

Annubar primary element is an averaging pitot tube similar to a single point pitot tube used to
measure the flow of gas, steam, or liquid in a pipe. An annubar primary element or Annubar
averaging pitot tube provides better accuracy than single point Pitot tubes. Pitot tube measures the
difference between the static pressure and the following pressure of the media in the pipe.

Fig. Annubar
Advantages:
 Low pressure drop
 Insertion without system shut down

Disadvantages:
 Not suitable for viscous and slurry applications
 Can be used only for clean fluids

VARIABLE AREA ROTAMETER

A rotameter is a device that measures the flow rate of fluid in a closed tube. It belongs to a class of
meters called variable area meters, which measure flow rate by allowing the cross sectional area the
fluid travels through, to vary, causing a measurable effect.

Fig. Variable area rotameter

Advantages:
 Pressure drop is constant
 No special fuel is required to pump
 Easy to construct

Disadvantages:
 Must always be vertically oriented due to its use of gravity
 Normally requires the use of glass otherwise user can’t see the float
  PRESSURE MEASUREMENT

Bourdon tubes

The Bourdon Tube is a non-liquid pressure measurement device. It is widely used in applications
where inexpensive static pressure measurements are needed.

A typical Bourdon tube contains a curved tube that is open to external pressure input on one end and
is coupled mechanically to an indicating needle on the other end, as shown schematically below.

Typical Bourdon Tube Pressure Gages

The external pressure is guided into the tube and causes it to flex, resulting in a change in curvature
of the tube. These curvature changes are linked to the dial indicator for a number readout.
Alternatively, a strain gage circuit can be attached on the tube to convert the pressure-induced
deflections into electric voltage signals. These signals can then be output electronically, rather than
mechanically with the dial indicator.

Pros and Cons

• Pros:

- Portable

- Convenient

- No leveling required
• Cons:

- Limited to static or quasi-static measurements.

- Accuracy may be insufficient for many applications. A mercury barometer can be used to
calibrate and check Bourdon Tubes.

 TEMPERATURE MEASUREMENT

The instrument most frequently used in case of temperature measurement is Thermocouples.

Fig. Thermocouple

A thermocouple is an electric device consisting of two different conductors forming electrical

junctions at differing temperatures. A thermocouple produces a temperature dependent
voltage as a result of the thermoelectric effect, and this voltage can be interpreted to measure
temperature. Thermocouples are a widely used type of temperature sensor.
Commercial thermocouples are inexpensive, interchangeable, are supplied with standard
connectors, and can measure a wide range of temperatures. In contrast to most other methods
of temperature measurement, thermocouples are self powered and require no external form of
excitation. The main limitation with thermocouples is accuracy.
 CHAPTER 6

UNDERSTANDING OF CONTROL SCHEME

 BINARY CONTROL SCHEME
CONTROL SCHEMES OF DEMINERALISE COOLING WATER PUMP

Need for automatic control scheme:-

The Power Generating Plant’s behavior can be seen by observing certain physical parameters,
which are the characteristics of the plant processes. The important process parameters are
temperature, pressure, flow; fluid levels, rotating speeds etc. The measured values of the most
significant of these parameters are transmitted from a plant to a Central Control Room (CCR)
where these are indicated to an operator.

For operating the plant at desired optimum conditions, the measured values of every
characteristic parameters have to be kept as close as possible to desired value. The
requirements are met by regulating the plant processes using process equipments like valves,
dampers; servomotors etc. so that the deviations of the measured values of characteristics
parameters from their desired values may be corrected.

High capital cost of modern day power plant necessitates its having extended life cycle. To
obtain this flexibility, efficient and safe operation, substantial degree of automatic control is
required to build in.

There are two types of Control systems;

 Open loop control system

 Closed loop control system

OPEN LOOP CONTROL;

No feedback loop is required and systems output is given to the final control element
irrespective of the consequences.

CLOSED LOOP CONTROL;

System utilizes the feedback to measure the actual system operation parameter being
controlled such as press, temp, flow, etc. The feedback signal is sent back to the
controller where is it compared with the desired system set point. The controller develops
an error signal that initiatives corrective action and derives the final output device to
desired value.
BINARY CONTROL SCHEME:-

BINARY/SEQUENCE CONTROL LOGICS:

Binary / Sequences control logic diagrams are prepared for all the drives controlled under station
C & I package. It is an open-loop sequence. These logic diagrams also include drives which are
supplied by customer and/or their vendors and the controls are provided by PEM(C & I). These
logic diagrams are prepared based upon the system write up of PEM(MSE) and write up / logic
submitted by the manufacturer of boiler/boiler auxiliary/turbine/turbine auxiliaries, balance
equipments, boiler feed pumps etc.

Typical binary scheme contains:-

1. Permissive for start/stop

2. Condition for auto start/stop
3. Protection start/stop

Consider for DEMINERALISED COOLING WATER SYSTEM FOR T.G. AUX’S and
OTHER AUX COOLERS.

 The controls of DMCW system shall be from the central control room
(CCR) through OWS of main plant DCS.
 Pump emergency stop push button shall be provided local to the pump
drive.
 MO BFV open /close push buttons shall be provided on the integral starter
of the valves.
 All logic controls, process interlocks etc. shall be realized in DCS.

DMCW PUMPS FOR TG AUXILIARY CONTROLS/INTERLOCKS

(A) Pump Start Permissive Interlocks

 Common Suction Header Pressure -“Adequate”
 Pump Suction BFV - “Open”
 Pump Discharge BFV -“Close”
 Over Head Tank Level -“Normal”

Note:
 Alarm to be annunciated if permissive conditions are otherwise than above
 Pumps shall be started in sequence
INPUTS LOGIC OUTPUTS

PUMP START PERMISSIVE LOGIC

(B) Standby Pump Start Interlocks

 Common Discharge Header Pressure -“Low With Time delay”
 Individual pump discharge pressure -“Low”
 Working pumps - “Trips due to any fault”

(C) Pump Tripping Interlocks :

 Suction header pressure
 Discharge header pressure
 Pump discharge BFV
 Pump suction BFV
 Motor electrical protection
- “Very low with time delay”
- “Very high with time delay”
- “Close with time delay”
- “Closes”
- “Actuated”

Note: Alarm to be annunciated for above condition.

INPUTS LOGIC OUTPUTS

MISCELLANEOUS LOGIC
INPUT LOGIC OUTPUT

STDBY PUMP START INTERLOCK& PUMP

TRIPPING INTERLOCKS LOGIC
INPUTS LOGIC OUTPUTS

MISCELLANEOUS LOGIC
INPUTS LOGIC OUTPUTS

TG DMCW PUMP DRIVE INTERFACE

 INPUTS LOGIC OUTPUTS

MISCELLANEOUS LOGIC

INPUT LOGIC OUTPUT

MISCELLANEOUS LOGIC
 INPUT LOGIC OUTPUT

*SETPOINT ARE DECIDED AT SIGHT DURING COMISSIONING

MISCELLANEOUS LOGIC
 INPUT LOGIC OUTPUT

*SETPOINT ARE DECIDED AT SIGHT DURING COMISSIONING

MISCELLANEOUS LOGIC
INPUTS LOGIC OUTPUTS

NRML M/U TO DMCW O/H TANK IV DRIVER

INTERFACE
TG DMCW PUMP CONTROL SCHEME
LEGEND:

HTD HT DRIVE

SOE SEQUENCE OF EVENTS

OWS OPERATOR WORK STATION

/ACS TO ANALOG CONTROL SCHEME

LVS LARGE VIDEO SCREEN

BID BI-DIRECTIONAL DRIVE

BIDI BI-DIRECTIONAL DRIVE (INCHING)

 ANALOG CONTROL SCHEME
CONTROL SCHEMES OF HP BYPASS
HP BYPASS SYSTEM

• The bypass system would work in parallel with Turbine during load rejection in a coordinated
manner with steam generator. However during start up of Boiler to build matching steam
parameters required for turbine and also when load transfer to turbine, the bypass system
would function in a non-coordinated manner as per the operator demand.

• This system controls the steam pressure at HP turbine inlet before and during turbine start-up
as well as during turbine trip and shut-down conditions by the pressure control valves.

OBJECTIVE
• The most important feature of this system is to allow operation of the boiler independent of
the availability of the turbine.

• In the event of turbine trip, the boiler can be kept in operation and the bypass system provides
an alternative path for flow of steam from boiler to condenser.

• Thus the boiler need not be ignited during restarting of the unit and a considerable time and
oil is saved.

• Initial warming up of steam pipe line etc. during cold start-up.

• Keeps the boiler on fire even during large load throw-off.

• Minimizes safety valve operation during sudden load throw-off thereby reducing water loss
from the cycle.

• Control main steam and reheat steam pressure.

CONTROL SCHEMES OF HP BYPASS SYSTEM

• The pressure from the main steam line is measured by pressure transmitters and this value is
subtracted from the set value, this set point is set depending on the initial pressure condition
at the time of boiler firing and this is equal to the steam pressure ahead of bypass valve plus a
negative bias pressure.

• If this difference is >6ata then alarm gets on and if it becomes >8ata then the hp bypass valve
opens. This pressure value is fed to PI controller and then its given to drive control interface.

• If HP downstream temperature is very high or condenser vacuum is very low then it

automatically gets closed.

• The bypass shall open in about 3 seconds after initiation of signal from the following:

1. Generator breaker open

2. Turbine trip

3. Turbine load shedding relay operates

4. Deviation between set point and controlled variable exceeds an adjustable preset limit.

5. Manual action

6. Re-heater protection active.

 > 2% OPEN
OPEN

<2% OPEN

HP BYPASS SYSTEM PRESSURE CONTROL

If any of these valves is >2% opened i.e. bypass valve 1 or 2 then spray water isolation valve gets
opened and if both of them are closed i.e. <2% open then spray water isolation valve gets closed.
SPRAY BLOCK VALVE LOGIC
HP BYPASS SYSTEM MISCELLENOUS ALARMS

• The downstream temperature from the main steam line is measured and a set value is
subtracted from the measured value. The set point is set by the operator itself.

• If the measured value exceeds the temperature of 345 deg C then alarm gets on and if it
exceeds 360 deg C then the bypass valve closes.

• This result is fed to the PID controller which forms a rated signal for the control positioned
of the associated spray temperature valves.

• A positive feed forward proportional to the steam flow is processed with the PID controller
output signal of injection valve. Thus, independent of the temperature measuring signal,
amount of water proportional to the steam flow is injected during the opening of the bypass
valve.
 • The electro hydraulic actuators make it possible to attain short positioning time for spray
temperature control valves.

HP BYPASS DRIVE CONTROL

HP BYPASS TEMPERATURE CONTROL
CONCLUSION:
Power plant control system is the nucleus of the power plant operation. The reduction of operating
time through the management of the daily and periodic operation, improvement and ease of
maintenance, and improved efficiency while reassuring reliability and safety are all merits of power
plant control systems.

Project engineering management, being the core engineering division for design of power plant is a
great platform to start the process of learning about the power industry and the technical aspects of
the power plants. This division is a hub of learning an engineering activity which enables overall
understanding and provides a summate view of power plant.

Being part of Control & Instrumentation has enabled me to get an overall picture of the power plant
functioning and management. C & I engineering touches almost all parts of a power plant and this
makes the area of work very vast and interesting. Power plant automation has become very
challenging and dynamic field.

Also PA Fan under which primary air system have been lucidly detailed.

Thus in the changing social scenario, continuous demand of power has made longer down time of
power plant impossible. This in turn has made the job of power plant automation very demanding.

The challenging is not only towards the automation of new plants but there is an addition challenge
to modernize the control system of the existing plants.

Exposure to industry environment was a drastic change from normal training procedures and it has
provided a platform for learning and expanding our horizon.
REFRENCES ;

1. http://en.wikipedia.org/wiki/Thermalpower station
2. http://en.wikipedia.org/wiki/Deaerator
3. http://en.wikipedia.org/wiki/Economiser
4. http://en.wikipedia.org/wiki/Regenerativeheat exchanger
5. http://www.tva.gov/power/coalart.htm
6. http://images.google.co.in/images?um=1&hl=en&q=feed+water+heater&star
t=18&sa=N&ndsp=18
7. www.bhelpem.com