1. 1. PANKI THERMAL POWER STATION PANKI KANPUR PTPS
2. 2. By:V IKAS TIWARI Electronics &comm . B.TECH FINAL YEAR B.t.kit dwarahat Presentation on Industrial Training CONTROL & INSTRUMENTATION DIVISION
3. 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. 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. 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. 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. 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. 8. Basic Principle
9. 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. 10. Efficient Operation of the plant. Economic Operation of the plant. Safe operation of the plant. Pollution control
11. 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. 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. 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. 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. 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. 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. 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. 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. 19. Bellows: Manufactured from Brass, Brass alloys, Stainless steel. Used for low pressure measurement. For high pressure measurement bellows are connected with spring.
20. 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. 21. Measurement of Temperature Temperature can be measured only by using indirect methods.
22. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 43. WEBSITE OF UVRVUNL www.uprvunl.gov REPORT OF PREVIOUS YEAR INTERNS USER GUIDE OF VARIOUS INSTRUMENTS IN PLANT PRESENTATIONS ON slideshare.com