At 92MW Thermal Power Plant Ultratech Cement Ltd.

Kovaya

Prepared By:

1) Parmar Nirav B. 2) Ladhani Ajaj T. 3) Parmar Prakash S.

Guided By: Mr. A.K.Singh (Manager E&I) Mr. Manuraj Shukla (Manager C&I) All Staff of C&I Department

A.V.Parekh Technical Institute- Rajkot

This is to certify that Mr. Parmar Prakash S. Parmar Nirav B. Ladhani Ajaj T. Of Diploma

Instrumentation &Control Eng Class, Roll No: S-143307047 S-143307050 S-143307009 Has satisfactorily completed his term work in Industrial Training

(S-601) for the term ending in June-July 2010

Date- / /2010

Mr. Manuraj Shukla

Mr. A.K.Singh

Index Name
Section:1
Coal Handling Plant 1.1 Introduction 1.2 equipment of coal handling plant 1.2.1 Truck Tripler 1.2.2 Primary Crusher 1.2.3 Stacker 1.2.4 Reclaimer 1.2.5 Secondary Crusher 1.2.6 Conveyor Belts 1.3 Instruments in C.H.P 1.3.1 Zero Speed Switch 1.3.2 Pull Cord Switch 1.3.3 Belt Sway switch 1.3.4 Metal Detector 1.3.5 Magnetic Separator 5 5 6 6 6 3 3 4 4 4 4 1

Page

Section :2
Lime Stone Handling System 2.1 Introduction 7

Section: 3
Boiler 3.1 Introduction 3.2 Principle of CFBC Boiler 3.3 Combustion Equipment 3.3.1 Furnace 3.3.2 Cyclone Separator 3.3.3 Lighting up Burner 3.3.4 J Valve Material Returner 3.3.5 Boiler Drum 3.3.6 Water Wall and Down Comer 3.3.7 Economizer 3.3.8 Feed Water System 3.3.9 Blow Down of Boiler 3.3.10 Super Heater 3.3.11 Primary Air Fan (PA Fan) 3.3.12 Secondary Air Fan (SA Fan) 3.3.13 P-Fan 3.3.14 Air Preheater 3.3.15 Platent Super Heater 3.3.16 Bottom Slag Cooler 3.3.17 Fly Ash Handling System 3.3.18 Flue Gas Desulphurization Process 11 12 12 12 14 14 14 15 15 16 16 16 16 17 17 17 19 21 9 10

3.3.19 Induced Draft Fan (ID Fan)

21

Section:4
Turbine 4.1 Introduction 4.2 Centrifugal Pump 4.3 Auxiliary Equipment 4.3.1 Low Pressure Heater (LP Heater) 4.3.2 High Pressure Hater (HP Heater) 4.4 Air Cooling condenser 4.5 Dearator 4.6 Feed Water and Steam Cycle 24 25 26 26 27 23 24

Section: 5
Description of Instruments 5.1 Bimetallic Thermometer 5.2 Resistance Temperature Detector 5.3 Thermocouple 54 Motor Operated Valve (MOV) 5.5 C-Type Burdon Tube 5.6 Pressure Switch 5.7 Differential Pressure Transmitter 5.8 Limit Switch 5.9 Control Valve 29 29 30 31 32 32 33 34 35

5.10 Rotameter 5.11 Pneumatic Type Cylinder Actuator 5.12 Zirconia O2 Analyzer 5.13 Current to Pressure Converter 5.14 Magnetic Float Level Transmitter 5.15 Magnetic Float Operated Switch 5.16 Hydrstep Electronic Level Gauge System of Drum 5.17 Solenoid Valve (SOV) 5.18 Motor Driven Damper 5.19 Metal Pipe Float Flow Meter 5.20 Proximity Senor 5.21 Magnetic Pick-up Type Speed Senor 5.22 Eddy Current Type Vibration Sensor

36 36 37 38 38 39

39 40 41 42 42 43 44

Section: 6
Introduction of D.C.S 6.1 Introduction of D.C.S 45

ACKNOWLEDGEMENT

This is the acknowledgement for those personalities who have helped me directly or indirectly to organize my training, helped me during my training period and to make my training report. I am also thankful to all staff members of Instrument department, who have helped me to clear my doubts & concepts.

Introduction

Gujarat Cement Works, UltraTech Cement, is setting up a Thermal Power Plant of 92 MW (4x23MW).
TPP comprises of: -- Four Steam turbines of 23 MW. -- Four CFBC Boilers. -- Fuel & Ash handling Plants, Water & Effluent Treatment plants. -- Power evacuation system and other associated ancillary equipments. -- Boilers are of multi fuel capability and steam produced in the boiler is utilized for spinning the Turbines that are coupled to the Electrical Generators which produces electricity

Thermal power plant includes the following systems and main components:
1) Boiler and auxiliaries 2) Steam Turbine and auxiliaries 3) Electrical systems 4)Auxiliaries system which includes mainly the water treatment system, fuel handling system, cooling water system, instrument and service air system, ash handling system etc.

Section: 1 Coal Handling Plant

1.1 Introduction

Coal handling plant is first stage of power plant. The main purpose of C.H.P. is to maintain required amount of coal and supply coal at a time in boiler combustion process. Coal handling plant contains two crusher, 9th conveyor belts, stacker. Reclaimer, truck Tripler & some instrument for operation of whole C.H.P. in automatic mode through distributed control system (D.C.S.) General block diagram of C.H.P. showing in fig. In this power plant four types of coal are used: 1). Pet cock 2). Indigenous 3). Imported 4.) Lignite

Coal handling plant is start from truck Tripler and end at boiler bunker. Whole plant operated trough DCS & interlock system which prevent any accidental condition. In plant stacker & reclaimer operated through PLC also they are connect with interlocking system.

1.2 Equipment of Coal Handling Plant

1.2.1) Truck Tripler

Truck tripler is first part of coal handling plant at witch all trucks having coal are unloaded, truck tripler operate by hydraulic system and one operator operate the tuck tripler, the tuck loaded with coal are stay at platform, when coal require in coal handling plant then hydraulic system operate by operator the platform with truck will goes up from one end. Through truck tripler coals pass on C1 conveyor belt and go to crushing in primary crusher.

1.2.2) Primary Crusher

The coal comes from C1 conveyor belt are going to crushing in primary crusher. This crusher use to crush the coal in 15mm size. It contain two separate crusher

1) Primary crusher 1 2) Primary crusher 2

Any one of them is use at a time for crushing. The operator select crusher through gate valve on operation requirement. Position of gate valve can sense by proximity switch which give limit of valve to D.C.S operator. The coal above 15mm size will restricted

by scraper and pass on bucket elevator. The bucket elevator contain bucket which go upward and pass coal on scraper conveyor. This coal will go to re-crushing through scraper conveyor. After crushing coal go to stacker through C2 belt.

1.2.3) Stacker:

Stacker is P.L.C operated machine which use for making stack between two tracks of reclaimer for storing purpose. One operator will operate the stacker with screen touch display and give different commands to it on their basic requirement. Stackers contain one conveyor belt trough which coal from C2 will go to stack. Stacker will go forward or backward trough tracks and wheels. The base of conveyor also moves right or left with requirement of operator. All movement of stacker is sense & control by limit switch which arrange at different moving part of it. It contains water spray for prevention of dust.

1.2.4) Reclaimer

When amount of coal is less in boiler bunker then coal is required to feel up the bunker and also for combtion process of boiler reclaimer is also P.L.C operated machine and use to take coal from stacks of coal and supply coal from plant requirement. Reclaimer also operate by one operator with screen touch display and interconnect with interlock of D.C.S reclaim contain bucket wheel and one horizontal conveyor belt at center of bunker wheel reclaimer go forward and backedward same to stacker and bucket wheel of reclaimer moves left or right horizontally on conveyor belt when reclaimer stack by operator. Bucket wheel is rotate and take coal from stacks. One side of bucket wheel opened for drop the coal on the conveyor belt. These coal transfer on c3 conveyor belt through belt of reclaimer. The coal from c3 belt pass on c5 belt goes forward for crushing in secondary crusher.

1.2.5) Secondary Crusher

The coal from c5 conveyor belt goes in the secondary crusher for crushing part and working of crusher is same as primary crusher but main difference is size of crushing it is 8mm in secondary crusher after crushing this coal pass on c6 conveyor belt. Through which is passed on C7a and C7b conveyor belt with the use of gate valve this coal I store in boiler bunker.

1.2.6) Conveyor Belt

Conveyor belt made from rubber and available in different thickness size as per requirement there are 9 conveyor belts from C1 to C7ab. All conveyor belts are rotate by high voltage motor. Work of all conveyor belt except all are giving with different equipment of C.H.P The C4 conveyor belt placed at underground for emergency coal supply in condition of fault in stacker. Reclaimer or crusher. All conveyor belt are inter connected in D.C.S interlock if any one of them is stopped due to faults then all conveyor belt stopped for prevent damage on the conveyor of plant. The pull cord switch placed both side of belt for stopped conveyor belt in accidental condition belt sway switch is placed on both side of conveyor detection sway of belt from there limit due to over loading. Rotors are placed under the conveyor belt for smooth work of conveyor belt

1.3 Instrument in C.H.P

1.3.1) Zero Speed Switch

The main function of zero speed switch is to give signal when any conveyer belt stopped due to any problem or damage in it. This switch is fitted with shaft of rotor at the end of any conveyor belt. Mostly proxy switch is used on zero speed sensor. Proximity switch is arranged at one side of iron shaft and this iron shaft is connect with conveyor rotor. When conveyor belt run rotor is rotate with its normal speed so shaft with rotor will also rotate. Proxy switch generate pulse each time. When iron plate target of shaft come at the face with proxy switch. When any belt stopped due to any problem then shaft will stopped and iron plate with shaft will also stopped so that proxy switch dose not generate the pulse and it will detect by D.C.S logic and all conveyor belt stopped according to its logic.

1.3.2) Pull Cord switch

Pull cord switch is on-off type switch which change their contact when we pull the link of switch. It is used mostly in conveyor belt system for prevent accidental condition at belt area. Many pull cord switch is placed at two side of belt and link of all pull cord switch are jointed with wire or other link at both side of belts. When any accident or fire or any dangerous condition occurs in convoy belt area then these switch is pull by any person who worked their, then the contact change in switch and system will stopped at there required arrangement. Mostly normally closed (NC) contact is use in pull cord switch because fault detection is easy in normally close (NC) contact.

1.3.3) Belts Sway Switch

The main function of this switch is to stop the conveyor belt and to show the fault when the conveyor belt sway beyond set limit, this switch enable over-swaying which protect the conveyor from damage and ensure easy running, because of uneven loading of material and worn out idler roller bearing over swaying is possible, shift reset is on of the main characteristic of the roller, belt sway switch is connected to the both side of the conveyor belt the contact between the switch and conveyor are possible by the switch the activation of the internal switch happen when the conveyor belt sway from their position

1.3.4) Metal Detector

Metal detector use in C.H.P (Coal Handling Plant) for detection of metel in coal. It prevents expansive repair and production breakdown it will detect all kind of metal like aluminum. copper. Iron etc The metal detector consists of two components. The probe and amplifier both o which are connected through one axial cable. The probe consists of two planner probes one of which will be mounted underneath the conveyor belt while the other probe will be held over the belt by special support. Working A high frequency alternating voltage is fed from the amplifier to a coil in the probe via a 75 Ohms coaxial cable this generate an electromagnetic field. If a metal peace come in to this field induction current will be generated will be sensed by amplifier depending on sensitivity

1.3.5) Magnetic Separator

The magnetic separator is use on conveyor belt which separate the metal particles from the coal. This magnetic separator contain magnet having high magnetic field. Due to this magnetic field the metal part with coal re removed the magnetic separator is placed in starting belt of coal handling plant

Section: 2

Limestone Handling System

2.1 introduction

Limestone is mostly use in boiler combustion process. It will use with coal in boiler because of high heat conjunction. Showing on fig. first limestone come in bunker then goes in bucket elevator through conveyor belt. Bucket elevator contain bucket which lifted up the lime stone through bucket elevator lime stone go to crushing of 8mm size will restricted by sampler and go to re crushing through scraper conveyor & bucket elevator After crushing lime stone goes in silo through pipe conveyor. Silo is use to store the lime stone when lime stone required in boiler then lime stone will supplied from silo through high pressure,

Section: 3 Boiler

3.1) Introduction

The power production enterprise is called power plant. The simple flowing chart of the production procedure of fossil fired power plant can be expressed by figure block diagram. Fuel is burning in boiler, the released heat will heat the water in boiler, and this water will be evaporated and overheated into superheat steam with certain temperature and pressure. This superheat steam will go into turbine through pipes. The steam will work in turbine by expansion and roll up the steam turbine to rotate the generator for generate electricity. After work in turbine, the steam will be exhausted into condenser, and cooled by the ACC fan. After cooling pressure of cooling water rising by pump, this condensate water will go into LP heater to be heated. After removing oxygen in deaerator , the pressure of it will be raised by feed water pump , and then it will be heated by HP heater and then go back to boiler to go on doing the above circulating process. From the above circulation, we will know there is a energy transformation course of three kinds of energy in power plant: the chemical energy in the fuel is transferred into the heat energy of steam in boiler; the heat energy of steam is transferred into mechanical energy in steam turbine; the mechanical energy is transferred into electric energy in generator. The important equipment in the course of energy transformation ---- boiler, turbine and generator are called three main equipments in power plant.

3.2) Principle of CFBC Boiler

The technology of circulating fluidized bed is a kind of clean combustion technology. Its special combustion way reduced the releasing amount of SO2 and Nox in coal fired power plant that are the main source of air pollution in world, i.e. it solve the problem of acid rain fundamentally. Fluidization refers to the air flow cross the material on air arrangement device under certain speed to make the particle of material contact with air flow to transfer into the state that is similar with fluid. The type of fluidized bed is depended on the flow velocity on the section of empty bed. Along with the rising of the velocity of air flow, the drag force produced by air flow to the material particle in bed is balanced with the gravity and buoyancy worked on the particles; the material in bed gets to rapid fluidized state from static bed condition through boiling, and turbulent state. the mixture of the material in bed is uniform and the fluidization is stable. The material in bed is brought out of furnace by high speed air, and it is caught by air solid separator, and then this part of material is sent into fluidized bed to combust again by material returning system.

3.3) Combustion Equipment

3.3.1) Furnace

The furnace is composed by front wall, rear wall and two side walls. At the bottom of furnace, the pipes of rear become sparse and from the bottom of air room and the air arrangement plate of fluidized bed. Two coal feeding openings and two limestone openings are set at the front wall of furnace above air distributed plate. Two rows of secondary air openings are installed at the front wall and rear wall of furnace; there are 5 up secondary air opening at single side, and 6 down secondary air opening at single

side. There are three ash extraction openings installed evenly at the bottom of furnace, the middle one is emergency ash extraction opening; the outlet of flue gas of furnace is at the top of rear wall.

3.3.2) Cyclone separator

One inlet flue duct of cyclone separator is installed in boiler. It connects the outlet of flue gas of back wall of furnace with cyclone separator, and form a air seal flue gas duct. The upper half part of cyclone separator is cylinder, and the lower half part is cone. The outlet of flue gas is cylindrical steel plate forming a cyclone whose end is opening and whose length will reach the certain position of cyclone separator. The fine particle and flue will flow to the bottom of cylinder, and then flow awards to leave cyclone separator. The coarse particles fall into the vertical pipes connected with J shape material returning device directly.

3.3.3) Lighting-up burner

Two air duct igniters are installed under bed for every boiler; the heat capacity of ignition burner is designed according to 30% boiler maximum continuous output; and it is arranged at elevation place of two side walls. The fuel used for ignition is fuel highspeed diesel oil, and the oil gun is mechanical central oil back type, there are two oil guns.

3.3.4) J valve material returner

The bed material and ash separated by steel plate type cyclone separator flow downwards through back material vertical pipes laying fire-resistive material and are discharged to J valve. J valve material back device is installed under cyclone separator, and it is supported on the beam of framework. It has two key functions: make the re-circulating bed material return to furnace continuously and stably from cyclone separator; supply seal between the negative pressure of cyclone separator and positive pressure of lower burner. The static pressure of separator is very near to the atmospheric pressure, the pressure of the material returning point of burner is very high because of primary air, so the seal between them must be supplied. The air distribution is adjusted by manual and motor-driven governing valves to realize sending certain amount of air. Pressure measuring point is set on vertical pipes to realize the monitor for material level

3.3.5) Boiler Drum

Drum is one of the most important equipments in natural circulation boiler. It is connected with the outlet pipe of upper header of water wall, outlet pipe of economizer, and the outlet pipe of centralized down comer and the outlet pipe of saturated steam. In one hand, it composes the circulation loop for evaporation; in the other hand, it accepts the feed water coming from economizer and sends saturated steam to superheater. So it is key position for the connection of heating, evaporation, and superheat. It is a cylinder shape metal container collected boiler water and saturated steam, has certain heat storing and relief ability.

3.3.6) Water Wall and Down Comer

Water wall is the important steam heating surface that is arranged around the furnace, top of furnace and air arrangement plate. Water wall can absorb the radiating heat released in the combustion of fuel in furnace, and then transfer this heat to the water or mixture of steam and water in pipes to evaporate a part of water. Down comer is an equipment that can send the water in drum into the down header of water wall and then into water wall continuously without interruption.

3.3.7) Economizer

Economizer is a kind of equipment that uses the heat energy of fuel gas at the end of boiler to heat the feed water. After adopting economizer, the Gas temperature leaving AH is reduced; and the temperature of feed water is increased; the material is saved, and the differential temperature between feed water and the wall of drum is reduced. The economizer is arranged inside of the vertical well of boiler, and it is composed by three horizontal pipes.

3.3.8) Feed Water System

Feed water system is the important compositing part of drum. It is composed of feed water pipe, economizer, drum, re-circulating pipe and relevant parts. Its task is supplying water to boiler and absorbing the heat of flue gas to improve the temperature of feed water. The feed water of the boiler is guided to the inlet header of the economizer in tail flue duct firstly, and then the feed water refluxes upwards into the outlet header through the pipe teams of economizer that are horizontally arranged, and then the feed water goes into drum from the right end plate of drum through the guide out pipe of economizer

3.3.9) Blow down of Boiler

The feed water gone into boiler has salt content, and the boiler water will corrode the boiler to produce corrosion product. So, the boiler water will contain various dissolved and un-dissolved impurities more or less. Although the impurity content and corrosion produce in the feed water of boiler is very small, but the salt content brought away.. The too big salt content in boiler water not only pollutes the steam but also scales on the heating surface of water wall or even corrodes the heating surface. Blow down of boiler is one of the most important methods to improve the quality of steam. In power plant, there are two blow down methods: periodic blow down and continuous blow down.

1. Periodic blowdown is done at the down header under the water wall of boiler. Its task is removing the water dross accumulated at the lower part of boiler and the soft deposition produced after phosphate treatment. The time of periodic blow down is very short, but the ability of removing the deposition in boiler is very strong.

2. The continuous blow down can blow down the boiler water whose thickness is biggest from the surface of boiler water continuously. Its aim is reducing the salt content in boiler water and preventing the too high thickness of boiler water from affecting the quality of steam.

3.3.10) Super heater

The working characteristic of super heater is called steam temperature characteristic; it refers to the variation relationship between the load of boiler and the temperature of steam. Generally, the temperature of the steam of convection super heater will be increased along with the increasing of load. the temperature of flue gas of the outlet of furnace increases, so the differential temperature of heat transformation is increased. The heat absorbing amount of unit steam increases, so the temperature of super heater steam rises. There are two types of super heater: 1.) 2.) Primary super heater Finishing super hater

3.3.11) Primary Air Fan (PA-Fan)

Primary air fan send a certain amount of air with oxygen to the dense phase area at the bottom of furnace to support the combustion at the same time. These primary air is feed in air chamber of furnace and air come in furnace through nozzles. The head pressure and amount of primary air is decided by the speed of fluidization, the characteristic of fuel, the combustion in furnace, the heat transformation, and so on. The amount of primary air is 40~70% of total air amount.

3.3.12) Secondary Air Fan (SA-Fan)

Secondary air fan is second centrifugal fan in power plant which use to give secondary air in furnace for make up the oxygen combusted in boiler and increase efficiency of combustion process.It can prevent from too high temperature of flue gas in partial area and reducing the discharging amount of NOx.

3.3.13) P-Fan

P-fan is also suction fan same as ID-Fan. Which sucked air from primary air line and pass at head of coal feeder at furnace. The coal feed into furnace uniformly; the combustion efficiency can be improved to make the temperature in furnace become uniform.

3.3.14) Air Preheater

Air preheater uses the residual heat of flue gas to increase the temperature of air, that improves the thermal efficiency of boiler greatly and strengthen the combustion in boiler. The air preheater can be divided into two types: 1) Primary air preheater. 2) Secondary air preheater. The primary air and secondary air go in air preheater with different pressures in pipes and exchange heat with the flue gas flowing outside the pipes. The arrangement of flue gas and air is crossed. The temperature of the air at outlet is 199 C. with these heated air efficiency of furnace combustion process and less time required for burning of coal.

3.3.15) Platen superheater

The platen superheater has two pieces arranged at the upper part of furnace and near to the front wall of furnace. The superheater is membrane structureThe whole platen superheater expands from the lower part to upper part. The outlet header of platen superheater is installed at the upper part of furnace. Steam outlet from primary superheater will go in platen super heater and steam heated with furnace temperature.

3.3.16) Bottom Slag cooler

There are two multi-pipe water cooling type drum slag cooler arranged under the normal slag outlet at the bottom of furnace. the high temperature material rotates along with the small barrel of several built-in spiral blade, and the material is transferred continuously; the cooling water goes through the intermediate layer between small barrels continuously and uniformly and exchange heat with the high temperature slag indirectly, in this way the high temperature material is cooled; the temperature of cooling water rises and it can be used again. The slag cooler is composed by material feeder, heat exchanging barrel, discharging device, driving device, base frame, rotating joint, and control tank and so on. The variable frequency governing speed control is adopted, the speed can be governed continuously according to the carbon content in a large range of slag, and it is benefit for steadying the pressure of bed.

3.3.17) Fly Ash Handling System

The boiler use coal & limestone for combustion process. The small particles of bed material which fly in flue gases is called fly ash. For reduce pollution these fly ash will removed with different techniques.

Here fly ash removed by two ways: 1) Trough shoot blower in second pass 2) Through Bag filters Fly ash remains in flue gases will passed trough second pass of boiler with negative pressure of induced draft fan. When it will pass trough second pass of boiler some fly ash particle restricted by pipe lines of super heater &economizer .due to these reason amount of fly ash particle increase at pipe line surface. so, it will effect on heat transformation process. These fly ash particle will removed by shoot blower. It placed in two side of second pass at different stage as per requirement. Main steam use by shoot blower &it is operated at require time period. it shoots steam on pipeline surface. Than fly ash particle will go downward and store in Dom valve. Trough service air it will go in fly ash silo for storage purpose.

3.3.18) Flue Gas Desulphurization Process (FGD)

Desulphurization can be done for CFBC. But the desulphurization efficiency of it is lower. If higher desulphurization efficiency is wanted, the required molar ratio Ca/S should be very large. A large amount of CaCO3 will be added to influent the combustion. The fly ash with plenty of CaO also will be discharged into atmosphere at the same time. The utilization rate of desulphurization absorbent is lower, but the operation cost is very high. And the emission cannot reach the standard of 200ppm. So, the lime is put into CFBC directly to attend combustion, the fly ash with calcium oxide will go into the following circulating bed device with flue gas; this calcium oxide will attend reaction in absorbent silo and produce lime hydrate and the further desulphurization reaction is finished. Because the active ability and quantity of superfluous lime in the fly ash of CFBC is enough for further desulphurization of circulating fluidized bed behind furnace, the adding amount of absorbent is reduced greatly, so that the operation cost is reduced. In this way, lime slaking device, lime

hydrate storage device, and material feeder are not required for flue gas desulphurization device o CFBC. All in all, the total operation cost of CFBCFGD is less.

3.3.19) Induced Draft Fan (ID-FAN)

Induced Draft fan is a suction type fan. This fan is kept near the chimney. It is centrifugal type & generates negative pressure.With these negative pressure the flue gas generated by combustion process will induced to pass through different auxiliary equipment of boiler & go forward toward chimney . Fig. shows the ID-FAN with detail of motor used for fan and also different parts & instrument use to control the rate of ID-fan.In Thermal power plant the ID-fan is work properly is most needful because the rate of Negative pressure effect on Boiler combustion process. The rate of suction is control by change the position the stem of pneumatic power cylinder .then the blades of fan will open or close with Accordance to adjustment. The supply air to cylinder will filtered & regulated by air filter regulator .The current to pressure converter will convert the input current supplied by operator into proportional pressure. The position of stem is detect by proximity sensor which gives output in 42mA range proportional to stem position.

Section: 4

Turbine

4.1) Introduction

Steam turbine is one of the important equipment of coal base thermal power plant; turbine, boiler, and generator compose the three primary equipment of coal base thermal plant. It has many advantages compared with other rotating machinery, such as the rotating speed of it is high, the power of single unit is large, its efficiency is high, and it is safe and reliable and so on. The history of steam turbine has been more than 120 years since 1883, the Swiss engineer G.G.P.de Lawaer built the first 3.67KW steam turbine which has utility value; in this century, it has been developed with the aim of increase the capacity of turbine, raise the parameters of steam, improve the material and the manufacturing technology, and improve the level of automatization. For the present, the capacity of single unit has been more than 1300MW. 25MW unit was built in 50th 20 century by our country, the operation history of it has been 50 years; its technology has been improved for many times, and it has adopted many advantaged control technology such as CCS and DEH and so on, its economic ability and safety can be guaranteed. In principle, the steam turbine is composed by stator and rotor, in order to guarantee the safe and stable operation of rotor, the following systems have to be fixed in turbine, the control system, lubricating system, centering support system, and the necessary auxiliary equipment and systems used to guarantee the working medium economic circulation and recovery. So, the main technical characteristic is the technology is highly concentration for the subjects and fields concerned metal, physical, chemical,

thermal, heat transfer, mechanical production, mechanical vibration, auto control, I&C protection and so on, and the picture 1 is the sectional drawing of a small steam turbine.

4.2) Centrifugal Pump

The feed water pump, condensate water pump, circulating water pump, drain water pump and so on in fossil power plant mostly are centrifugal pump. So the centrifugal pump is indispensable important auxiliary equipment in power plant. Its safe and economical operation can influence the safe and economical operation of power plant directly.

4.3) Auxiliary Equipment

4.3.1) LP heater 1. Regenerative heating system: The purpose of adopting regenerative heating system for extraction heating steamwater in turbine equipments is to reduce cold source loss and improve heating economy of unit. So the steam that has worked in turbine is extracted from some middle stages and then is led to regenerative heater to heat boiler feed water and main condensate water. Heat enthalpy of this part of extraction steam is used fully and not taken by cooling water. Total steam consumption of turbine is increasing after adopting regenerative heater, but heat consumption and coal consumption of turbine is decreasing. The reason that steam consumption of turbine is increasing is that the work that is done by per kg new steam in turbine is decreasing. The reason that steam and coal consumption is decreasing is that coal source loss is decreasing and then feed water temperature is increasing, so heat economy is improved after adopting regenerative heating system. Heating surface and heat stress of boiler are reducing because of increasing feed water temperature, so stability of equipment is improved.

4.3.2)HP heater 1. HP heater is one kind of regenerative heater. The influence of it to the economy and load of fossil fired power plant is very large. It has the same functions with LP heater, except the medium flowing in pipes changes into HP feed water. When the HP heater exits the operation completely, the change of the amount of extraction changes the pressure reducing of every stage of turbine and the flow of steam, so the stress suffered by baffle of the rotor blade is increased and the temperature of feed water of boiler is reduced directly in addition. If you want to keep the original evaporation capacity, the amount of fired coal must be increased, that may cause over temperature of the superheater of boiler. And the operation of HP heater is stopped at the same time, and this increases the heat loss of exhaustion in condenser and reduces the thermal efficiency of the circulation of unit. So when the operation of HP heater is stopped, the load of unit should be limited.

4.4) Air Cooling Condenser (ACC)

ACC transfers exhaust steam into condensate, then gives condensate to water circulation. Exhaust steam comes from turbine gets into ACC steam collection header through steam pipe. In the steam collection header, steam falls down in fin tubes in A frame. The steam in tubes is condensate by air come from fan. The condensate will be collected in the steam collection header and gets the bottom of A structure; then goes to CRT (hot well). We use condensate pumps pump condensate water to condensate water header, gland seal cooler and LPH, at last, gets to deaerator. The un-condensate is exhausted by steam ejector.

4.5) Deaerator

The deaerator is adopted method of thermal removing oxygen; it not only removes oxygen, but also removes other gas in water. Heat boiler feed water by steam in to separate out the gas in water and remove it. During heating, pressure of the steam that is around water is increasing greatly, pressure of other gas is decreasing gradually, when water is heated to relevant saturated temperature of this pressure, the pressure will be close to total pressure of water, pressure of other gas is dropping to zero, so the gas in water is out.

4.6) Feed Water and Steam Cycle

Feed water is main requirement of thermal power plant because feed water is converted into steam by high temperature of boiler and passing through superheater and

economizer for make pure steam. Turbine is rotate by this pure steam at maintained temperature and pressure. After use in turbine this exhaust steam is passing through auxiliary cooling control (ACC). This steam will condense by cooling air of large size of fan and convert into water. Water from auxiliary cooling control is add with make up water for getting required amount of water in process.

Pressure of these feed water will increase with boiler feed pump. With this pressure the feed water is passed through different auxiliary equipment and arrives at boiler pump. First this high pressure feed water passing through low pressure heater (LP heater) and heated by low pressure stage of turbine. This feed water contain dissolved O2 which affect on boiler tube like corrosion and erosion so this dissolved O2 content removed in dearator by second stage exhaust steam of turbine. After dearating process temperature of feed water is increase by high pressure heater. In high pressure heater (HP heater) water is heated by high pressure exhaust steam of turbine. After HP heater feed water pass through economizer and heated by flue gases. The hot feed water will increase efficiency of steam generation process. Then feed water is goes in high temperature boiler for making of steam. In boiler feed water is convert into steam but this steam contain moisture so it will pass trough three super heater this super heater convert steam into pure steam The pressure. Temperature and flow of steam is maintain on required rate and given to turbine. This feed water to steam cycle will continuously work in plant for generation of power

Section: 5

Description of Instruments

5.1) Bi-metallic thermometer

The bi-metallic element consists of two strips of different metals, with different thermal expansion coefficients, inseparably joined together. This strip is spirally or helically wound with one end fixed to the body of the thermometer, and the other attached to the axis of a pointer. Measurement of temperature is made with the bi-metallic system inside the temperature sensor. Temperature variation influences the bi-metallic strip such as to rotate the pointer; this rotation is indicated on a dial.

5.2) Resistance temperature detector (RTD)

An RTD (Resistance Temperature Detector) is basically a temperature sensitive resistor. It is a positive temperature coefficient device, which means that the resistance increases with temperature. The resistance of the metal increases with temperature, The resistive property of the metal is called its resistivity. The resistive property defines length and cross sectional area required to fabricate an RTD of a given value. The resistance is proportional to length and inversely proportional to the cross sectional area,

5.3) Thermocouple
The working principle of thermocouple is based on three effects, discovered by See beck, Peltier and Thomson.

Working of thermocouple The general circuit for the working of thermocouple is shown in the figure 1 above. It comprises to two dissimilar metals A and B. These are joined together to form two junctions, p and q, which are maintained at the temperatures T1 and T2 respectively. Remember that the thermocouple cannot be formed if there are no two junctions. Since the two junctions are maintained at different temperatures the Peltier emf is generated within the circuit and it is the function of the temperatures of two junctions. If the temperature of both the junctions is same, equal and opposite emf will be generated at both junctions and the net current flowing through the junction is zero. If the junctions are maintained at different temperature, the emfs will not become zero and there will be net current flowing through the circuit. The total emf flowing through this circuit depends on the metals used within the circuit as well the temperature of the two junctions. The total emf or the current flowing through the circuit can be measured easily by the suitable devise.

5.4) Motor Operated Valve (MOV)

MOV consists of a motor, an actuator, and a valve. Figure 1 shows a schematic diagram of an MOV. A motor that is bolted to the actuator housing drives the actuator. The pinion gear, which is attached to the motor shaft, drives a gear train. Normally, there are two different switches that control the MOV: a geared limit switch and a torque switch. Usually, the geared limit switch is used to stop the valve stroke at a previously determined position, and the torque switch is used to secure the required stem thrust. After the motor turns off, it continues to rotate due to the inertia of moving parts that further increase the stem thrust. Typical estimated motor torque signature and measured stem thrust signature of one full stroke are shown in Figure

5.5) C-Type Bourdon Tube Gauge

These are used for measurement of pressure and vacuum and are suitable for all clean and non-clogging liquid and gaseous media. The Bourdon Tube is a thin walled tube of oval cross section which may be of C form or spirally wound. This tube expands when pressure is applied internally; this expansion is converted into rotation of a concentric pointer with a gear movement. The reading indicated on a dial by the pointer is proportional to the pressure applied. C-type Bourdon tubes are used for low pressure ranges and helical / spiral tubes for higher pressure ranges.

5.6) Pressure Switch

The pressure is fed to the inside of a bellows which carries a contact one plat. When the pressure reach a sufficient (or preset) value, the contact plate touches contact plates, thus closing an electrical circuit to an alarm or motor control gear. The flexibility of the bellows ensures that the plate makes adequate contact with both points and gives a slight rubbing or wiping action that keeps the contact area clean. A pressure switch turns ON or OFF at a preset pressure. This pressure is called set point of the switch. A pressure switch is used in some form of control, e.g. to operate a solenoid valve at given pressure, or start up a pump.The pressure switch is usually a microswitch or a mercury switch. A bourdon tube, A diaphragm or a bellow can be used to actuate the switch .generally pressure switch actuate a relay.

5.7) Differential Pressure Transmitter

OR Differential Pressure Flow Meter

The use of differential pressure as an inferred measurement of a liquid's rate of flow is well known. Differential pressure flow meters are, by far, the most common units in use today. Estimates are that over 50 percent of all liquid flow measurement applications use this type of unit. The basic operating principle of differential pressure flowmeters is based on the premise that the pressure drop across the meter is proportional to the square of the flow rate. The flow rate is obtained by measuring the pressure differential and extracting the square root. Differential pressure flow meters, like most flow meters, have a primary and secondary element. The primary element causes a change in kinetic energy, which creates the differential pressure in the pipe. The unit must be properly matched to the pipe size, flow conditions, and the liquid's properties. And, the measurement accuracy of the element must be good over a reasonable range. The secondary element measures the differential pressure and provides the signal or read-out that is converted to the actual flow value.

5.8) Limit switch

A limit switch is used to stop the motion of a machine slide or element once it reaches a fixed point. An example of limit switch use is in machining components on automatic machine tools like lathes and special purpose machines. Attributes like holes, bores, etc. have a fixed depth. Once the cutting tool has to cut through the required depth, the slide must be stopped or else it will dash against the component sides. Working of a limit switch The basic limit switch has a spring-loaded push button connected to an electrical circuit. When the push button (actuator) is pushed inside it trips or activates the electrical circuit. The electrical circuit then signals a machine element to stop or start its motion. Once the pressure on the push button is removed, it comes back to its original position and is ready for the next cycle.

5.9) Control Valve

The current-to-pressure transducer (I/P), which sends a pneumatic signal to the control valve. The control valve position changes in response to the signal to adjust flow to the set point. As the flow changes, it is sensed by the flow transmitter. When the flow sensed is equal to set point, the valve position remains the same. Any time there is a disturbance to the system or a change in set point, the flow control loop automatically responds to achieve the programmed set point. A block diagram of this concept is here. The final control element can be proportional control or ON-OFF control. For ON-OFF control, a controller output relay changes the state of the relay contact, which completes the circuit for a solenoid valve to energize. The solenoid valve opens to allow air to open (or close) a control valve. A typical I/P transducer is a force balance device in which a coil suspends and hangs in the field of a magnet. Current flowing through the coil generates axial movement of the coil, which causes movement of the beam. The beam controls the backpressure against the nozzle by controlling the restriction of airflow through the nozzle. This backpressure acts as a pilot pressure to control the outlet pressure. The typical I/P transducer is calibrated for a 4-20 mA input = 3-15 psig output. Most I/P transducers can be configured for direct action (output pressure increases as input signal increases) or reverse action (output pressure decreases as input signal increases).

5.10) Rotameter

Rotameter are the most widely used type of variable-area (VA) flowmeter. In these devices, the falling and rising action of a float in a tapered tube provides a measure of flow rate (see Figure). Rotameters are known as gravity-type flowmeters because they are based on the opposition between the downward force of gravity and the upward force of the flowing fluid. When the flow is constant, the float stays in one position that can be related to the volumetric flow rate. That position is indicated on a graduated scale. Note that to keep the full force of gravity in effect, this Dynamic balancing act requires a vertical measuring tube.

Other forms of gravity-type VA meters may incorporate a piston or vane that responds to flow in a manner similar to the floats behavior. All these devices can be used to measure the flow rates of most liquids, gases, and steam. There are also similar types that balance the fluid flow with a spring rather than gravitational force. These do not

require vertical mounting, but corrosive or erosive fluids can damage the spring and lead to reduced accuracy.

5.11) Pneumatic Type Cylinder Actuator

The piston is covered by a diaphragm, or seal, which keeps the air in the upper portion of the cylinder, allowing air pressure to force the diaphragm downward, moving the piston underneath, which in turn moves the valve stem, which is linked to the internal parts of the actuator. Pneumatic actuators may only have one spot for a signal input, top or bottom, depending on action required. Valves require little pressure to operate and usually double or triple the input force. The larger the size of the piston, the larger the output pressure can be. Having a larger piston can also be good if air supply is low, allowing the same forces with less input. These pressures are large enough to crush object in the pipe. On 100 kPa input, you could lift a small car (upwards 1,000 lbs) easily, and this is only a basic, small pneumatic valve. However, the resulting forces required of the stem would be too great and cause the valve stem to fail.

This pressure is transferred to the valve stem, which is hooked up to either the valve plug butterfly valve etc. Larger forces are required in high pressure or high flow

pipelines to allow the valve to overcome these forces, and allow it to move the valves moving parts to control the material flowing inside.

5.12) Zirconia Type O2 Analyzer

When stable zirconia (YHZ) obtained by adding CaO to ZrO2 is heated to more than several hundred degrees centigrade, the conductivity of oxygen ions increases. If a platinum electrode is installed on both sides of this element, oxygen ions move in accordance with the difference in the concentration of oxygen between the two electrodes, where electromotive force then occurs. The measured potential difference is in proportion to the logarithm of partial pressure ratio of oxygen. Therefore, the oxygen in the sample gas can be found by sending a reference gas to one of the electrodes. Since the measurement cell itself is at a high temperature, some of the relevant analyzers allow it to be inserted directly into the exhaust combustion gas. The zero calibration cannot be performed for such a gas as contains no oxygen, e.g, when an N2 gas cylinder is used. In such a case, an oxygen cylinder for about 10% of the range is used for this calibration. In the case of the limiting current type analyzer, electric potential is applied between the zirconia electrodes. The oxygen concentration limited by gas dispersion holes is in a proportional relation with the limiting current and this current value is detected. This analyzer is easy to handle because it requires no reference gas, its output is linear, and the reading is stable even at around 21%.

For the zirconia type oxygen analyzer, since its element reaches a high temperature, the oxygen decrease involved in the oxidation and combustion of combustible gases becomes negative interference

5.13) Current to pressure converter (ItoP)

The I/P provides a reliable, repeatable, accurate means of Converting an electrical signal into pneumatic pressure. Its force balance principle is a coil suspended in a magnetic field on a flexible Mount. At the lower end of the coil is a flapper valve that operates against precision ground nozzle to create a backpressure on the servo diaphragm of a booster relay. The input current flows in the coil and produces a force between the coil and the flapper valve, which controls the servo pressure and the output pressure. Zero adjustment of the unit is made by turning a screw that regulates the distance between the flapper valve and the air nozzle. Its purpose is to translate the analog output from a control system into a precise, repeatable pressure value to control pneumatic actuators/operators, pneumatic valves, dampers, vanes, etc.

5.14) Magnetic float level transmitter

Magnetic float level transmitter are made for continuous level of liquid. Transmitter consist of magnetic sensor enclosed inside a sealed stem. A magnetic float move up and down between the operating range with the rise and fall of liquid level. The magnetic float actuates the magnetic sensor circuitry inside the steam the output value of array changes in corresponds to rise and fall of liquid level. This output value of array is

sensed by a transmitter circuitry which converts the signal into 4-20 mA current output proportional To the liquid level inside tank,

5.15) Magnetic Float Operated Switch

This switch is operated by two magnets use for sensing of level. This switch having two contacts NO&NC. Shown in fig of switch for level measurement the magnet in pipe goes up with liquid due to buoyancy effect & come at front of switch then inner magnet of switch is attracted due to magnetism of float magnet and the contact will change with movement of inner magnet. Then change in contact will give level which is high or low according to liquid level,

5.16) Hydrastep

Electronic level gauge system of drum

The hydrastep electronic level gauging system is designed as an electronic alternative to water level gauges on boilers. Giving a more reliable and safe water level indication then conversional visual gauges. It uses the significant difference in resistivities of water and steam in temperature up to 370c (698F) to determination the water level. A vertical row of electrodes is installed in water level column attached boiler drum. The resistance measurement is made between the insulated tip of each electrodes and the wall of column.

The cell constant defining the actual resistance measured I determined by the length and diameter of electrode tip and the column bore. In practice, the constant is chosen so that the resistance in water Is less then 100k Ohm and steam resistance is greater then 10M Ohms. Since the resistivities of water and steam are substantially different.

5.17) Solenoid Operated Valve (SOV)

Solenoid valve is a control element which is used to material in to the process. it I two positional or on-off type control element and operate by electrical supply AC or DC. It is simple made up of a plunger which is a simple iron rod & one coil of fine wire I wound on this plunger. When AC or DC supply given to coil then current flow in coil and produced magnetic field. Due to this magnetic field the plunger is lifted by magnetic force from its rest position. As we disconnect supply top mounted spring force plunger back to normal position. Solenoid valve generally used in plc based instrumentation. It also used in level control system & tripping system.

5.18) Motor Driven Damper

The motor driven damper could be used for air and flue gas system of power plant boiler. It has the function of isolating & cut of the medium flowing or regulating the floe rate based on shapes. It could be divided into circular damper and rectangular damper. The damper is composed of external casing disk bearing shaft sensing and transmission device. The damper operated on either locally or remote mode. These damper operate through motor. Open with according to command on motor.

5.19) Metal pipe float Flow Meter

The flow meter adopts variable area measuring principle. The measuring device is composed of one taper measuring pipe and floater. The floater can move freely up and down in the taper measuring pipe. When the flow changes. The vertical position of the floater inside the measuring pipe changes correspond through magnetic transmitting system the position of the floater is transmitted to the dial scale of the indicator to indicate the flow,

5.20) Proximity Sensor

Inductive proximity sensors operate under the electrical principle of inductance. Inductance is the phenomenon where a fluctuating current, which by definition has a magnetic component, induces an electromotive force (emf) in a target object. To amplify a devices inductance effect, a sensor manufacturer twists wire into a tight coil and runs a current through it. An inductive proximity sensor has four components; the coil, oscillator, detection circuit and output circuit. The oscillator generates a fluctuating magnetic field the shape of a doughnut around the winding of the coil that locates in the devices sensing face. When a metal object moves into the inductive proximity sensors field of detection, Eddy circuits build up in the metallic object, magnetically push back, and finally reduce the Inductive sensors own oscillation field. The sensors detection circuit monitors the oscillators strength and triggers an output from the output circuitry when the oscillator becomes reduced to a sufficient level.

5.21) Magnetic Pick-up Type Speed Sensor

This type of speed sensor is mostly use in industries because it sense the speed with out contact of rotating device. This sped sensor contains magnetic pick-up probe and soft iron core with coil wound on it. Rotor contain ferromagnetic tooth of same size and same distance between them when rotor rotate, the ferromagnetic tooth comes at front of probe. The alternating voltage generate in coil at each time when tooth come at front of probe. This voltage is proportional to speed of rotating device.

Section:6 Introduction of D.C.S & P.L.C

6.1) Introduction of D.C.S

The Engineering Workstation (EWS) is for project development, including configuration of graphics, logic, alarms, security, etc. Typically, the EWS is a PC running Windows 2000/XP. The Operator Workstation (OWS) provides the operator interface, including color graphics, faceplates, alarms, logging, trends, diagnostics, etc. The EWS includes an OWS for testing and troubleshooting. Typically, the OWS is a PC running Windows 2000/XP.

The Field Control Unit (FCU) executes sequential and regulatory logic and directly scans I/O. Depending on the FCU's configuration, you can scan multiple brands of I/O from one unit. The FCU runs QNX, a real-time operating system, and is typically a PLC or a ruggedized industrial computer available in a variety of form factors. The I/O Subsystem supports I/O from all the standard industry suppliers. In a UCOS configuration, you don't necessarily need PLCs just PLC I/O. The UCOS microFCU is a small PLC that executes sequential and regulatory logic and directly scans onboard I/O. It is a cost-effective alternative in situations where low cost, low power consumption, and/or low point counts are called for. The SCADA Data Server (SDS) interfaces UCOS to PLCs, Fieldbus technologies, RTUs, PLC I/O, and other third-party devices. The SDS can execute sequential and regulatory logic and directly scan supported I/O. It can also act as a data gateway allowing UCOS to work with just about any device you can think of. Typically, an SDS is a ruggedized industrial computer running Windows 2000/XP, although direct I/O scanning is run under QNX, the leading real-time operating system. The Process Historical Archiver (PHA) stores and retrieves historical data collected by the FCU, microFCU, SDS, or any other intelligent device in the system. The PHA can run standalone or can share an OWS workstation. Typically, the PHA is a PC running Windows 2000/XP. UCOS supports redundant and non-redundant fiber optic and Ethernet local networks using the TCP/IP networking protocol for standardized, advanced application connectivity.