Professional Documents
Culture Documents
Scheme briefing in classroom: Boiler Drum connections, feed regenerating heating system, air,
and flue gas path. Classroom briefing on fuel oil system and milling system Classroom briefing on
mainstream, cold reheat; hot reheat lines, condensate & feed water lines, BFP, CW schemes.
Classroom briefing on hydrogen cooling, stator water, seal oil, switchyard, GT, UAT, breakers, bus
bars, 66 KV / 420 KV switchgears.
Scheme Tracing: Coal handling receiving points, stocking lines, weighing, sampling, screening,
crushing, bunker filling, conveyors, tension arrangement for conveyors.
Oil Handling: Unloading arrangements, oil tank mountings, oil pump house connections, tank
heating and tracing heating, pipe line layout with provisions for expansion
Boiler Feed Water Schemes: Feed control station arrangement, economizer connections,
economizer re- circulation lines, boiler drum water wall connections, drain header, blow down
lines, CBD, IBD expanders, SH/RH attemperator station.
Air and Flue Gas Schemes: Location of FD, PA, Seal Air, IF Fans, Fan control devices, damper
arrangements, primary air, secondary air and flue gas paths, Scanner air, seal air schemes, Wind
box and burner arrangement, Fuel Schemes, Scheme of RC bunkers and RC feeders, coal mill
connections, Light oil and atomizing air system, location of trip valves, control valves, nozzles
valves, igniters, Heavy oil and atomizing steam system
Water Treatment Plant Raw water tanks to DM water storage tanks, arrangement of Pr. Sand /
Activated carbon filters, cat ion, anion, mixed beds, degasifying lines, provision for back
cooling, regeneration, phosphate and hydrazine dozing scheme.
Ash Handling: Bottom Ash disposal, BAH (bottom ash hopper) arrangement, clinker grinder,
HP/LP water injection, fly ash disposal arrangements, ash slurry pump house, slurry sumps, pump
connections.
Steam Schemes MS, CR & HRH lines up to turbine control valves including HP/LP by pass,
location of safety valves, vents and drains, auxiliary PRDS schemes, auxiliary steam distribution,
soot blowing steam lines
Steam Extractions and Drains: Schemes of turbine extractions, FCNRVS, heater drain
connections, HP/LP drips. Schemes for heating flanges and studs, Steam connections / condenser
air line connections to ejectors, unit drain tank / flash tank connections.
Condensate and Feed Water Schemes: CEP connections, scheme of condensate flow, ejectors,
gland steam coolers, LP heaters, de-aerator connections. Scheme of feed water flow, BFP
connections, feed water connection to HP heaters, location of valves, interconnections, bypass
arrangement for heaters
Turbine Oil System: Turbine lube Oil schemes, lube Oil purification schemes, location of MOT &
lube Oil pumps, oil coolers, cooling water connections
Concept and layout of Control and Instrumentation in Thermal Power Plant, Various transducers,
sensors used in power plants. Secondary instrumentation and measurement systems. PLC and DCS.
Analytical instruments and anlysers. Protection and interlocks of Boiler, Turbine and their auxiliaries,
Introduction to auto control, Auto control loops used in thermal power stations, Turbovisory
instrumentation. Parameters limits, Basic concepts of measuring devices, Analytical Instrumentation
for boiler Water, Steam, Flue Gas, H /O /CO Introduction to MAX DNA.
Introduction to new / latest technology in Control and Instrumentation in modern thermal power
station.
General Protection Neutral earthing, stator and rotor earth faults, sustained external faults,
instability, protective systems used.
Introduction: Safety, Role of operation engineers, Unit operation, some general operating
instructions, Shift routine.
Operation of boiler and auxiliaries: Line-up Boiler feed water system, Line-up Boiler water and
steam system, Boiler filling, Draft system, Fuel firing system, Boiler purging and lighting up,
Boiler loading, Normal shut down to coal, Auxiliary steam system, Routine Checks, Emergency
operations, Boiler Feed Pump Operation , Introduction, Preparation for Start-up, BFP Start Up,
Conditions for Tripping of Operating Feed Pump, Recommended Annunciations for each BFP &
Auxiliaries.
Operation of turbine & auxiliaries: Line up, Starting of turbine from cold state, Rolling
instructions, Loading the turbine, Warm and Hot start, Hot start, Planned shutdown, Important
instructions during turbine running, Do’s and Don’ts during turbine running, Emergencies in
turbine and auxiliaries , Governing System Operation, Salient Operational Points, Turbine start up
with various Governing modes, Response of EHC to load rejection, Important Governing System
Annunciations and Indications.
Operation of KWU turbine & auxiliaries: Lineup, Cold start up, Loading the turbine, Start up
after 48 hrs shut down, Start up after 8 hours shut down, Normal shut down of turbine, Emergency
shutdown, Do’s and Don’ts for turbine operation, Operation of Turbine governing system.
TURBO-GENERATOR OPERATIONS
Operation of generator & auxiliaries: Lining up the system, Pre- Synchronizing checks, Steps for
generator synchronizing, Routine operation and periodic checks, Operational limits of 210MW
Generator, Emergency operation, Operation of generator cooling system, stator and hydrogen
cooling, Operation of Generator excitation system AVR.
Operation of auxiliaries Availability of electrical supply to the equipment, source feeder of each
equipment points of isolation of the equipment, locking during isolation, permit to work system,
Boiler pre light up checks, meaning of light up, shut down, tripping, starting etc., No pending
permits, local checks, Operation of service auxiliaries, cooling water pump, compressors,
auxiliary steam, fuel oil pump, Operation of air-pre heater and ID fan, Rechecks, flow path line
up, permissive interlocks, Operation of FD & PA Fans, pre checks, flow path line up, permissive,
interlocks, Mill operation, pre checks, flow path line up, permissive, interlocks, FSSS, Secondary
air, burner tilt, fuel and air control, Drum level control, Super Heater, Re- Heater, temperature
control and their interlocks, Operation of turbine lubricating system and barring gear, Operation of
condensate and feed water system, BFP, Heaters CEP, HP/LP Bypass operation and turbine
heating, Turbine rolling and synchronization
Unit loading and shut down sequence, Operational difference between cold start up, warm
Introduction, Need for performance monitoring, objective, controllable and uncontrollable factors,
basic requirements, Factors influencing performance of boilers and optimization Fuel properties,
excess air, fines of P.F. etc
Air Heaters effect of AH outlet temperature, performance tests Fans Performance, curves,
optimum operating point
Factors influencing performance of turbine Steam pressure, temperature and back pressure,
cylinder efficiency, deposits on turbine blades, blade roughness, effect of loading, Turbine Losses.
Factors affecting performance of condenser and feed heater TTD, CW inlet, temperature, CW
flow, heat transfer across tubes.
Heaters air accumulation, steam side / water side fouling drainage, effect of attemperator in
reheaters Heat balancing,
a. Interpersonal relationship
b. Leadership
c. Communication skill
d. Team Building
e. Time Management
Module 10: Advanced Steam Generation & Technology-Supercritical and Fluidized Bed
Combustion Technology (FBC, CFBC & Supercritical Technology)
Historical development, Basics of fluidization and its principle, Classification of FBC boiler,
Bubbling, Circulating fluidized bed boiler, Operation & Maintenance of FBC Boiler, Efficiency
and Performance of Boiler, Basics & Historical Development of supercritical technology,
Advantage of supercritical technology, Supercritical Boilers & Turbine, Construction details of
boiler & Turbine, Efficiency & Performance of the supercritical Power plant, Water chemistry
for supercritical Boiler
Module 11 : Power Plant Metallurgy, Corrosion, Non Destructive Testing & Welding
Basic chemistry Atomic structure, elements, compounds, mixtures, solutions, ionization, salts,
acids, alkalis, pH values, Pre and post treatment of water, Chemical control and treatment of Boiler
feed water and steam, Cooling water treatment, Classification of coal & oil, their sampling and
analysis, Corrosion theory and deposition in Boiler, Energy and ecology definition of eco system,
effect of energy on ecology and concept of green house effect, Legislation and standards for noise
air and water pollution and rehabilitation policy, Water pollution due to thermal power station,
Water pollutant and their effect on eco-system, waste treatment, zero discharge concept, Air
Pollution caused by coal and oil at source and due to combustion of coal and oil, stack emission,
ESP, etc. Disease caused due to thermal power plant pollution and other impact. Environmental
impact, assessment and environment audit, Introduction to Ecology and Environment ,Types of
Pollution ,Effects of pollution ,Air Pollution and Control Methods, Water Pollution and Control
Methods, Solid Wastes and Removal, Environmental Legislation and Standards, Environmental
Audit, Environmental Impact Assessment
UNIT II (Metallurgy, NDT and Welding)
Introduction to Metallurgy and its relevance in power industry – crystal structure – space lattices –
crystal lattice imperfections – crystal structure under stress. Elastic and Plastic deformations
strain hardening and fracture – Mechanical properties of materials – Testing of materials, Heat
treatment and surface hardening of steel - failure mechanism – typical such situations in a power
plant.
Material selection of Design, Material requirement, specification and relevant standards for boiler,
turbine, generator components – Piping and Valves: Appreciation of component, fabrication – metal
forming, casting – forging, pipe bending, tube manufacture,
Defect analysis and life assessment, Low temperature behavior – high temperature behavior –
defect assessment of solidification crack austenite stainless steel welds, Cracking in Cr. MOV
weldment etc. Thermal fatigue - various tests – defects assessment route and calculation of
damage – remaining life assessment beyond design life of boilers, turbine rotors, generator rotors
etc. Introduction to welding and types of welding, Description of welding methods generally used
in thermal power station, Welding machines, types of electrodes, precautions during welding
process, welding defects, Purpose of NDT and types of defects covered by NDT, NDT Methods
used in power station Principle, equipments, utilization, merits and de-merits
Aims and objective of maintenance efficient service, high plant availability, maintenance and
planning engineer’s duties, Integration of maintenance with operational requirements, plant
reliability, plant outages and daily work programs, Preventive maintenance of running units,
Planning of major plant overhauls during shutdowns Planning techniques – critical path analysis,
charting system etc. Purchasing and stores control – standards, cost codes, control of stores and
store records, Cost control, direct costs, indirect costs, outage costs, budgeting and costing work,
budgetary control, Contract procedures (Conditions of contract, capital applications and
procedures, project evaluation, interest and depreciation charges
Checking of boiler tubes for external damage due to erosion or cutting, Method to overcome for
example, Strengthening of tubes in the flow channels, Hydraulic test, allowable rate of pressure
drop, Checking of welds and pin holes, External cleaning of boiler surface and water, Use of sky
climber, Measurement of tube wall thickness, Different types of tube failures, creep over-
heating, Checking of flue gas path for direct corrosion or erosion and leakage, checking of
isolating and regulating dampers for leakage, proper alignment leak adjustment for multi louver
dampers both under cold and hot operation conditions. Boiler bottom air seal, proper and free
movement and expansion of boiler setting when hot. Normal water level and flow in bottom seal
PA, ID & FD fan check for inlet dampers, bearing alignment, vibration both radial and axial shift
of magnetic centre of motor and rotor, fan blade conditions mode of repairs, hard facing,
Checking of boiler mountings and their adjustments (a) Gauges glasses, (b) Safety valves, their
checking and settings of safety valves for blow down and dropping Checking the burner nozzle for
burnout and reasons for the same and its metallurgy, Check the flow distribution in burners
adjustment of orifices or valves check the burner flow direction and its adjustment, checking of
burner chamber, dampers breakage of links and proper gauge operation, Check the rollers or ball
wear of coal mill as also bull ring segment wear, Keeping records of capacity and hour of
operation, Troubleshooting causes and remedies, Soot Blowers Maintenance / Trouble shooting
causes and remedies, Safety valve maintenance and its floating procedures, Troubleshooting /
causes and remedies, Adjustment and prevention of dust accumulation in the seal chamber,
Maintenance and inspection of oil system turbine oil coolers, maintenance of condensate side
and steam side tubes, Condenser tube maintenance, off load and on load tube cleaning
procedure
Generator Maintenance: stator – checking of overhang winding, clamp and shields, loss wedges
and overheating, Rotor checking of shaft earthing arrangement, hydrogen seal and leakages
(purge test) loss wedges, end ring for cracks, overheating, Insulation resistance and winding
resistance, Transformer maintenance – insulation testing drying out routine maintenance Motor
Insulation checking, terminal checking, phasing out, motor drying, Cable jointing, material and
techniques, Testing , Commissioning , Operation & Maintenance of EHV Transformers ,Circuit
Breakers ,General Construction of Cables Installation ,
Commissioning & Maintenance of Station Batteries Electrical Generator Introduction, need for
Maintenance, Basic concept of Maintenance, Causes of Failure, Electrical Safety Aspect, Factors
Affecting the life of a transformer, Introduction, Various factors involved, New Insulating Oil
Characteristics, Recommended Oil characteristics in use,
Routine Power plant startup/Shut down, operations, cold/warm/hot start-ups, load changes,
handling plant emergencies and engineering analysis along with functional and maintenance
aspects of power plant equipments will be covered in simulator training throughout the
semester.
After completion of theory sessions and scheme tracing followed by on job operations training.
In this module, students will be sent in plant to trace the actual schemes of plant processes and
study them in depth. After completion of scheme tracing they will be deployed in plant (under
the supervision of plant faculty) to get hands on experience in the actual operation of individual
plant equipment.
In this module, students will be sent in plant to under the supervision of plant faculty to get hands
on experience in the actual maintenance of individual plant equipments. Following different
locations will be covered:
Provisions of Energy Conservation Act, 2001 , Energy Audit Report Structure , Measuring Tools and
tackles for audit , Energy Auditing of various components/ systems – Approach & methodology.
Various stages of planning, erection & commissioning of the plant, Project monitoring soft wares
and their applications.
Introduction to power System Planning, Power scenario in India Load Forecasting Generation
Scheduling and Economic Load dispatch Grid Management, Electricity acts and their amendments.
Power sector reforms and its future projections Various modes of power business. Tariff, PPA, ABT,
DSM, RTM and their implementations and impacts on power producers. SCADA and energy Management
System, VAR management Flattening of Load Curve, System Stability and load Frequency control, , Grid
Collapse and remedial measures.
Energy and ecology definition of eco system, effect of energy on ecology and concept of greenhouse
effect, Legislation and standards for noise air and water pollution and rehabilitation policy, Water
pollution due to thermal power station, Water pollutant and their effect on eco-system, waste
treatment, zero discharge concept, Air Pollution caused by coal and oil at source and due to
combustion of coal and oil, stack emission, ESP, etc. Disease caused due to thermal power plant
pollution and other impact. Environmental impact, assessment and environment audit, Introduction to
Ecology and Environment, Types of Pollution ,Effects of pollution ,Air Pollution and Control Methods,
Water Pollution and Control Methods, Solid Wastes and Removal, Environmental Legislation and
Standards, Environmental Audit, Environmental Impact Assessment
Training on MS Office and advance MS Excel and decision-making tools. Introduction to SAP and its
applications on material management, work planning modules.
Principles , construction and operation of nuclear power plant. Brayton, Carnot and Rankine cycles,
Theory and principles of Gas Turbine working. Theory and Principles of Gas Turbine working,
Construction details of Gas Turbine, Air compressors, Combustors Various type of starting arrangement
of Gas Turbines, GT auxiliaries. Combine cycle gas turbine, cogeneration and hybrid systems.
Environmental aspects of electric energy generation. Various types of renewable energy sources. Changing
scenario of power generation. Value of alternative and renewable energy sources, difference between
Conventional energy and renewable energy. Wind Energy Systems. Solar thermal power systems. Direct energy
Conversation – Solar Photovoltaic, Fuel Cells. Waste to Energy. Solar passive Architecture. Biomass Energy
Systems. Bio-Fuels RE and Grids Integration
Module 22 : Power transmission ,Concept of Smart Grid, RE integration and energy storage
technologies
Power transmission system, AC & DC transmissions. National grid, smart grid ,micro grid, challenges in
RE integration and its mitigation technologies. Battery storage, fuel cells, Hydrogen as future energy.
Transformation from conventional concepts to challenging scenario.
Introduction to Solar energy. Solar radiation and its measurement. Solar thermal energy collectors.
Solar thermal energy conversion systems. Solar photovoltaic system
Classification of wind turbines, aerodynamic operation of wind turbines. wind characteristics. Wind
power generation curve. Modes of wind power generation.
Wind energy farms. Estimation of wind energy potential and selection of optimum wind energy
generator. Grid interfacing of a wind form. Economics of wind farms.
Hydro power stations and its classifications. Classification of water turbines and their applications.
Hydro generators.
Biomass resources. Biofuels-Biogas, Producer gas, liquid fuels, Biomass conversion technologies,
Biochemical conversion. Biomass gasification. Biogas plants. Recovery from domestic waste and
vegetation. Power generation from liquid waste. Biogas cogeneration. Ethanol and biodiesel from
biomass.
Each Trainee will be required to carry out a project work in the form of live problem identification, its
analysis, synthesis and recommendations in the form of conclusions.
The project work will be carried out under the guidance of faculty from or outside the institute.
The final outcome of the project work shall be submitted by the trainee in the form of project report.
Report should be submitted within due date in the prescribed format neatly typed and spiral bound.
The evaluation of the project work will be on the basis of quality of project report in terms of its
contents, research and presentation.
Regards
Sabu Isac
Prof JIPT
8978880920