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- 1. PANKI THERMAL POWER STATION PANKI KANPUR PTPS
- 2. By:V IKAS TIWARI Electronics &comm . B.TECH FINAL YEAR
B.t.kit dwarahat Presentation on Industrial Training CONTROL &
INSTRUMENTATION DIVISION
- 3. S.NO CONTENTS 1 INTRODUCTION 2 BASIC PRINCIPLE 3 FUNCTION
DIAGRAM 4 VARIOUS DIVISIONS 5 OBJECTIVES OF CONTROL AND
INSTRUMENTATION 6 MEASURMENTS POINTS 7 LABS
- 4. The energy sector holds the key in accelerating the economic
growth of India. The energy demands for developing country like
India keep on continuously growing. Energy is a driving force
behind rapid economic growth of the country. India ranks tenth in
the world in total energy consumption. It is first requirement of
energy to accelerate the development of the sector to meet its
growth aspirations. The pattern of energy production put coal and
oil again on top. These account for 65% of the entire generation.
Renewable energy ranks bottom of the total production just before
the Nuclear energy. The distribution of energy resource like hydro
power is skewed towards North-eastern states of the country as 70 %
of the total hydro potential is located in the Northern and
North-eastern region.
- 5. It is the most traditional way of power generation. Setup
cost is lesser than other power project like neuclear,hydro &
wind. Coal is the basic requirement for that and in India coal is
easily available. Transport of vapour is easy because it is
lighter.
- 6. S NO. Name of the project No. of units Capacity (MW) Actual
Genera tion 1. Harduaganj (A,B&C) 10 630 375 2. Panki,Kanpur 4
284 210 3. Obra 8 550 480 4. Obra ext 5 1000 970 5. Anpara 5 1630
1630 6. Tanda(now under NTPC) 4 440 NIL 7. Pariksha,Jhansi 4 440
440
- 7. Panki Thermal Power Station is a Electricity Generation
Station where Electricity Generated through the steam operation on
Turbine & Steam is Generated by Coal Firing so it is a Typical
Coal fired Electricity Generation Station. It is Located about 16
Kms Away from Kanpur Railway Station ,was Started with two
units(1st & 2nd) of 32 MW each.it was established in 1968.
After Generating Power for about 28-29 years,2*32 MW units had
completed their Rated Life So they were closed on 30th November
1995 & 18th April 1997 respectively. So In 1976-77 ,Two Units
(3rd & 4th of 2*110 MW each) Manufactured ,Installed Bharat
Heavy Electronics Ltd. These units were established in 1976 &
1977 respectively. Unit 3rd & 4th have been derated to 105 MW
each by the Central Electricity Authority(C.E.A) on 11th January
1990. So Presently there are two units (3rd & 4th of 105 MW
each) working at PTPS.
- 8. Basic Principle
- 9. Water Treatment Division Coal Handling Division Boiler
Maintenance Division Turbine Maintenance Division Electrical
Maintenance Division CONTROL &INSTRUMENTAION DIVISION
Electrical Distribution Division Civil Maintenance Division
Operating General Division(O.G 1) Operating General Division(O.G.2)
Store & Purchase Division Store,Purchase & Transportaion
Division
- 10. Efficient Operation of the plant. Economic Operation of the
plant. Safe operation of the plant. Pollution control
- 11. This entire task is often taken up by control &
instrumentation or simply instrumentation system which has
following functions:- a) Measurement b) Control c) Operation d)
Monitoring e) Protection
- 12. For a Plant Measurement system needs to be: Very accurate
Reliable Delays should be as small as possible Should be switched
on manually when a overall control system fails. Pressure
Temperature Flow Level Expansion/ Contraction Analysis of (1) Water
(2) Steam (3) Flue Gases And Others
- 13. Variables/ Measuring Points Types Of Sensors/ Approx.
number Parameters Instruments in the plant (1) Pressure (a) Boiler
Bourdon Tube, (b) Turbine Diaphragm, (c) Turbine Throttle Bellows
375-400 (d) Furnace Bell Gauges (2)Tempera (a Steam at superheater
Thermocouple ture inlet & outlet (b Feed Water at economiser
inlet (c Water at condenser RTD 700-750 inlet (d Air Preheater (e
Flue Gases Thermocouple
- 14. (e Bearing of turbine & Thermocouple generator (f feed
pump, condensate RTD pump (3) Flow (a High Pressure Steam Orifice,
Venturi, 75-100 (b Feed water inlet Flow Nozzle,etc. (c Condensate
(4) Level (a Boiler Drum (b condensate tank Differential 75-100 (c
Water line pressure methods (5) Expansion (a Turbine Shaft Relative
6-8 (b Turbine casing Displacement (6) Vibration (a turbine &
generator Mass spring with shafts & bearing shells
Potentiometric Capacitive, eddy 30-50 current, piezo electric &
optical types are used
- 15. (7) Analysis (i) WATER (a feed water at econ- -omiser inlet
(b Boiler inlet Conductive cell 8-12 (c Condenser with meter (d
Condensate pump discharge (ii) STEAM (a Saturated steam Conductive
cell 4-6 (b Main line steam with meter (c Super heater inlet Na
Analyser 1-2 (iii) FLUE GASES (a O2 Economiser to air Zirconia cell
2-4 heater (b CO2 Air heater inlet CO2 analyser 2-4 & outlet (c
CO stack CO analyser 2-4 (d SO2 - Stack SO2 analyser 1-2 (e
Nitrogen Oxide- stack N- Oxide Analysesr 1-2 (f Dust concn.- stack
Optical method 2-3
- 16. Pressure measuring devices are divided into two groups:
Liquid Columns Expansion Elements Liquid columns: . Low range
pressure measurement May be of U-Tube type or well-Type. Unknown
Pressure
- 17. These are not favoured in modern power plant but are still
used in older power plants. Expansion Elements: Used in modern
power plants. Usually metallic & its movement indicates the
pressure. Either directly coupled with mechanical linkages or
indirectly by an electrical transducer connected to a read out
device . Main Expansion Elements are: Diaphragms. Bellows Bourden
tube
- 18. Diaphragms Commonly corrugated diaphragms are used because
large deflection can be produced without nonlinearity compared with
flat type. In order to increase the deflection capabilities two or
more corrugated diaphragms are welded at the circumferences---
Capsule element.
- 19. Bellows: Manufactured from Brass, Brass alloys, Stainless
steel. Used for low pressure measurement. For high pressure
measurement bellows are connected with spring.
- 20. Bourden Tube C shaped and made into an arc of about 270 0
Material from which it made depends upon the pressure range of the
device Bourdon tubes are also used in forms other than C type:-
Spiral element: large movement than C tube. Helical element:
produce more or less circular movement which is useful for driving
a recorder pen directly.
- 21. Measurement of Temperature Temperature can be measured only
by using indirect methods.
- 22. The most important parameter in thermal power plant is
temperature and its measurement plays a vital role in safe
operation of the plant. Rise of temperature in a substance is due
to the resultant increase in molecular activity of the substance on
application of heat; which increases the internal energy of the
material . The efficiency of generation also depend on the
temperature measurement T2 = Tempreture inside the condenser. T1=
Superheater temperature. 1T 2T 1
- 23. Expansion Thermometer In this type of measurement two
dissimilar metal tube having different expansion coefficient are
attached end to end. For same temperature change difference in the
lengths are compared and calibrated for unknown temperature
measurement. Variation in length is slight and has to be magnified
for detection.
- 24. THERMOELECTRIC THERMOMETRY This device is based on SEEBACK
and PELTIER effect. It comprises of two junctions at different
temperature. Then the emf is induced in the circuit due to the flow
of electrons. This is an important part in the plant. The actual
value depend upon the material used and on temperature difference
between the junctions.
- 25. RESISTANCE THERMOMETRY Suggested by Siemens in 1871- but
not satisfactory used for high temperature . Today RTD is given by
H.L.Calender in 1891 PROPERTY-The resistance of the conductor
changes when its temperature is changed. Copper is occasionally
used. Platinum, nickel or nickel alloys are commonly used .
Tungsten is used for high temperature applications METAL MIN. TEMP.
MAX.TEMP. MELTING POINT PLATINUM -260 0 C 110 0 C 1773 0 C COPPER 0
0 C 180 0 C 1083 0 C NICKEL -220 0 C 300 0 C 1435 0 C TUNGSTEN -200
0 C 1000 0 C 3370 0 C
- 26. RTDs ULTRA VIOLET SENSOR This device is used in furnace and
it measures the intensity of ultra violet rays there and according
to the wave generated which directly indicates the temperature in
the furnace.
- 27. A universal flow meter for all applications in power
station is not available. Infect there are more ways of measuring
flow than measuring pressure & temperature. Dual function
meters usually measure flow rate with linear output & minimum
error. Vortex & Ultrasonic meters have become available in
recent years (1986) & their full potential is not still fully
developed. Two principle measurements are made by flow meters viz.
quantity of flow and rate of flow. 'Quantity of flow' is the
quantity of fluid passing a given point in a given time, i.e.
gallons or pounds. Rate of flow' is the speed of a fluid passing a
given point at a given instant and is proportional to quantity
passing at a given instant, i.e. gallons per minute or pounds per
hour.
- 28. There are two groups of measuring devices:- 1. POSITIVE, OR
VOLUMETRIC, which measure flow by transferring a measured quantity
of fluid from the inlet to the outlet. 2. INFERENTIAL, which
measures the velocity of the flow and the volume passed is
inferred, it being equal to the velocity times the cross sectional
area of the flow. The inferential type is the most widely
used.
- 29. pH, DO,TURBIDITY & HYDRAZINE: Need to be checked for
acidity (pH), Dissolved oxygen(DO) Turbidity arising out of
contamination by suspended particles . Hydrazine which is added
from outside to the feed water but the excess should be monitored.
Oxygen reacts with thallium to form thallium oxide which in aqueous
solution show good conductivity.
- 30. 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 beings,
C&I in the same way controls and operates various motors,
pumps, etc and thus helps us to achieve our targets. C&I, as
the name indicates, is a branch in engineering which deals with
various measurement, indication, transmission and control in
different technical field. The main work of C&I department is
to observe, control and manipulate electrical as well as
non-electrical quantities like temperature, pressure,
vibrations.
- 31. C&I department governs the whole functioning and
operation of power plant through the Central Control System
(DDC-MIS) Distributed Digital Control Monitoring and Information
System.
- 32. Control and Instrumentation Department has following labs:
1. Manometry Lab 2. Protection and Interlocks Lab 3. Automation Lab
4. Electronics Lab 5. Water Treatment Plant 6. Furnaces Safety
Supervisory System Lab
- 33. 1. TRANSMITTERS It is used for pressure measurements of
gases and liquids, its working principle is that the input pressure
is converted into electrostatic capacitance and from there it is
conditioned and amplified. It gives an output of 4-20 ma DC. It can
be mounted on a pipe or a wall. For liquid or steam measurement
transmitters is mounted below main process piping and for gas
measurement transmitter is placed above pipe. 2. MANOMETER Its a
tube which is bent, in U shape. It is filled with a liquid. This
device corresponds to a difference in pressure across the two
limbs. 3. BOURDEN PRESSURE GAUGE Its an oval section tube. Its one
end is fixed. It is provided with a pointer to indicate the
pressure on a calibrated scale. It is of 2 types: (a) Spiral type:
for Low pressure measurement. (b) Helical Type: for High pressure
measurement.
- 34. INTERLOCKING It is basically interconnecting two or more
equipments so that if one equipments fails other one can perform
the tasks. This type of interdependence is also created so that
equipments connected together are started and shut down in the
specific sequence to avoid damage. For protection of equipments
tripping are provided for all the equipments. Tripping can be
considered as the series of instructions connected through OR
Gates. When a fault occurs and any one of the tripping is satisfied
a signal is sent to the relay, which trips the circuit. The main
equipments of this lab are relay and circuit breakers
- 35. Some of instrument used for protection are: 1. RELAY It is
a protective device. It can detect wrong condition in electrical
circuits by constantly measuring the electrical quantities flowing
under normal and faulty conditions. Some of the electrical
quantities are voltage, current, phase angle and velocity. 2. FUSES
It is a short piece of metal inserted in the circuit, which melts
when heavy current flows through it and thus breaks the circuit.
Usually silver is used as a fuse material . 3. MINIATURE CIRCUIT
BREAKER They are used with combination of the control circuits to-
a) Enable the staring of plant and distributors. b) Protect the
circuit in case of a fault. In consists of current carrying
contacts, one movable and other fixed. When a fault occurs the
contacts separate and are is stuck between them.
- 36. This lab deals in automating the existing equipment and
feeding routes. Earlier, the old technology dealt with only (DAS)
Data Acquisition System known as primary systems. The modern
technology or the secondary systems are coupled with (MIS)
Management Information System. All the control instruments are
excited by 24V supply (4-20mA) because voltage can be
mathematically handled with ease therefore all control systems use
voltage system for computation.
- 37. This lab has the responsibility of starting fire in the
furnace to enable the burning of coal.. Unburnt coal is removed
using forced draft or induced draft fan. The temperature inside the
boiler is 1100 degree Celsius and its height is 18 to 40 m. It is
made up of mild steel. An ultra violet sensor is employed in
furnace to measure the intensity of ultra violet rays inside the
furnace and according to it a signal in the same order of same mV
is generated which directly indicates the temperature of the
furnace. For firing the furnace a 10 KV spark plug is operated for
ten seconds over a spray of diesel fuel and pre-heater air along
each of the feeder-mills.
- 38. This lab undertakes the calibration and testing of various
cards. It houses various types of analytical instruments like
oscilloscopes, integrated circuits, cards auto analyzers etc.
Various processes undertaken in this lab are: 1. Transmitter
converts mV to mA. 2. Auto analyzer purifies the sample before it
is sent to electrodes
- 39. Electrical Maintenance Division: It is responsible for
maintenance of: 1. Boiler side motors 2. Turbine side motors 3.
Outside motors 4. Switchgear Protection By switch gear It makes or
breaks an electrical circuit.
- 40. Pollution Control systems: In order to ensure that NTPC
comply with all the stipulated environment norms, various pollution
control systems / devices as discussed below have been installed to
control air and water pollution. 1. Electrostatic Precipitators:
The ash left behind after combustion of coal is arrested in high
efficiency Electrostatic Precipitators (ESPs) and particulate
emission is controlled well within the stipulated norms. The ash
collected in the ESPs is disposed to Ash Ponds in slurry form. 2.
Flue Gas Stacks: Tall Flue Gas Stacks have been provided for wide
dispersion of the gaseous emissions (SOX, NOX etc) into the
atmosphere. 3. Neutralisation Pits: Neutralisation pits have been
provided in the Water Treatment Plant (WTP) for pH correction of
the effluents nbefore discharge into Effluent Treatment Plant (ETP)
for further treatment and use.
- 41. 5. Cooling Towers Cooling Towers have been provided for
cooling the hot Condenser cooling water in closed cycle Condenser
Cooling Water (CCW) Systems. This helps in reduction in thermal
pollution and conservation of fresh water. 6. Ash Water Recycling
System: In the AWRS, the effluent from ash pond is circulated back
to the station for further ash sluicing to the ash pond. This helps
in savings of fresh water requirements for transportation of ash
from the plant.
- 42. 1. The objective of industrial liquid effluent treatment
plant (ETP) is to discharge lesser and cleaner effluent from the
power plants to meet environmental regulations. 2. After primary
treatment at the source of their generation, the effluents are sent
to the ETP for further treatment. 3. The scheme involves collection
of various effluents and their appropriate treatment centrally and
re-circulation of the treated effluent for various plant uses
- 43. WEBSITE OF UVRVUNL www.uprvunl.gov REPORT OF PREVIOUS YEAR
INTERNS USER GUIDE OF VARIOUS INSTRUMENTS IN PLANT PRESENTATIONS ON
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