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NATIONAL POWER TRAINING INSTITUTEPOST GRADUATE DIPLOMA COURSE IN THERMAL POWER PLANT ENGINEERING

SYLLABUS

Sl.No. Subject / Module - First Semester

No. of Weeks

1 Power Plant Introduction & Industrial Safety 12 Power Plant Familiarisation 63 Power Plant Briefing & Scheme Tracing 24 Power Plant Operation 25 Rotation On-job(Operation) 5

6Erection, Commissioning & Construction Management 2

7Power Plant Performance & Efficiency Calculation 1

8Power Plant Chemistry , Metallurgy ,NDT & Welding 2

9 Gas turbine & Combined Cycle Power Plant 1

10Advanced Steam Generation Technology- Supercritical and FBC 1

11Business Communication & Personality Development 1First Semester Examination 1Subject / Module - Second Semester

12 Power Plant Protection 113 Energy Audit 1/214 Maintanence Planning & Cost Control 115 Nuclear Power Plant Familiarisation 116 Renewable and Hydro Power Plants 117 Maintanence Practice & Inspection 418 Design Analysis 119 Load Despatch 120 Power Reforms and regulations 121 Control & Instrumentation 222 IT Application in Power Sector & GIS 223 Environment Management 124 Rotational On Job(Maint.) 425 Training & visit to Mfrs. Works 226 Simulator 2

Project Presentation 1/2Margin For Holidays 1Second Semester Examination 1Total 52 1


Scheme of Examination

Distinction -75% and aboveFirst Division -60% & AboveSecond Division -50% to less than 60 %Pass Marks -Minimum 45% in internal & external examination separately and 50 % in overall SemesterA student failing in a particular semester in three or more subjects will have to repeat the Semester exam with the next batch. A student failing in a particular subject will have to appear in the subject exam.

Paper No. Title of the Paper - First Semester

No. of Weeks

Internal TestMax marks

External exam Max Marks

Total Max marks

Remarks

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Power Plant Familiarisation-I (Power Plant Introduction & Safety, Generators & transformers) 3 50 100 150

2Power Plant Familiarisation-II(Boiler, Turbine & BOP) 4 50 100 150

3Power Plant Operation, Power Plant Performance & Efficiency Calculation 3 50 100 150

4Erection, Commissioning & Construction Management, Gas turbine & Combined Cycle Power Plant 3 50 100 150

5

Power Plant Chemistry, Metallurgy, NDT & Welding, Advanced Steam Generation Technology- Supercritical and FBC 3 50 100 150

6 Rotation On-job(Operation) (Based on Viva Voce) 5 50 100 150

7Power Plant Briefing & Scheme Tracing(Based on Viva Voce) 2 50 50 100

8Business Communication & Personality Development(Based on Viva Voce) 1 50 50

Total 1050

First Semester Examination 1

Title of the Paper - Second Semester

1Power Plant Protection, Control & Instrumentation, Energy Audit 3.5 50 100 150

2

Maintenance Planning & Cost Control, Environment Management, Nuclear Power Plant Familiarization, Renewable & Hydro Power Plants 4 50 100 150

3 Maintenance Practice & Inspection, Design Analysis 5 50100 150

4Load Dispatch, IT Application in Power Sector & GIS, Power Reforms & Regulation 4 50 100 150

5. Rotation On-job(Maintenance) (Based on Viva Voce) 4 50 100 150

6Training & visit to Mfrs. Works(Based on Viva Voce) 2 50 50

7 Simulator 2 100100

8Project(Based on Viva Voce) 0.5 50 100 150

Margin for holidays 1

Second Semester Examination 1

Total 521050

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RULES AND REGULATION A. ADMISSION AND ELIGIBILITY

1. The duration of the course leading to the Post Graduate Diploma In Thermal Power Plant Engineering shall be one academic year(52 weeks) divided into two semesters.

A candidate shall have to pass all the two semester examinations within a maximum period of three years of his/her admission to the first semester of Post Graduate Diploma In Thermal Power Plant Engineering programme failing which he/she will be deemed to be unfit for the programme. However, a candidate, who having passed the first semester examination discontinues his studies, for legitimate and justified reasons may be permitted to join second semester within one year of his passing the first semester examination.

2. The minimum qualifications for admissions to the first semester of Post Graduate Diploma In Thermal Power Plant Engineering programme shall be a Bachelor degree in Engineering or AMIE or equivalent degree in Mechanical, Electrical, Electronics./Control & Instrumentation/ Power Engineering. Those appearing in their final year examination may also apply. However, they must submit their result at the time of counseling. The Admission to this P.G. Diploma will be done on the basis of Merit based on a Common Entrance Test (CET) followed by counseling. CET will be conducted on rotation basis by the Institutes in the sequence New Delhi, Nagpur, Neyveli and Durgapur respectively.

3.(a) The first semester examination shall be open to a regular student who

I) has been on the rolls of the Institute during the first semester;II) has at least 75% attendance in the class during the semester;III) has obtained pass marks in the internal assessment/

workshop/practical exam. andIV) bears a good moral character

(b) The second semester examination shall be open to a regular student who:

i) has been on the rolls of the Institute for the concerned semesterii) has at least 75% attendance in the class during the semester;iii) has passed the first semester examination and iv) bears a good moral character.

B. EXAMINATION AND FEES

4. Every candidate shall be examined in the subject(s) as laid down in the Scheme of Examinations/Syllabus prescribed . Course/Tuition fee should be divided equally into two parts. Semester 1 fee should be deposited at the time of counseling. Semester 2 fee should be deposited by 20th February of each year failing which a late fee of Rs.100/- per day may be charged. Each PGDC student will be charged a fee of Rs 200/- per subject as examination fee which

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may be deposited one month before start of the semester examination ie. Rs. 1600/- for first semester and Rs 1600/- for second semester.

5. The external examiner(s) will set the question papers as per the criteria laid down in the Scheme of Examination for the program. Evaluation of semester exam answer sheets will not be done in the same Institute. All the written semester exams will be of three hour duration.

6. The medium of instruction and examination shall be English.

7. Mobile phones, any extra piece of paper, notebook are banned in the exam hall. A student indulging in exam malpractices may be expelled by the invigilator/Chief Supdt. for one year from the exam and he will be able to take the semester exams only after one year.

8. The amount of examination fee to be paid by a candidate for each semester shall be as per the decision of NPTI from time to time.

9. The Examination for the first semesters shall ordinarily be held in the month of January and for the second semester in the month of July or on such dates as may be fixed by the Director General, NPTI.

Supplementary examinations will be held for re-appear/failed candidates as under:-

Semester When held

(a) First Semester Along with the Second Semester(b) Second Semester Along with the subsequent first Semester_________________________________________________________

10. The Course Coordinator of the concerned Institute shall forward the internal test marks to the Principal Director/ Director at least one week before the commencement of each semester examination alongwith list of the eligible students who have satisfied the requirements of rules for appearing in the Examination.

11. (i) As soon as possible, after the competition of the examination the Principal Director/ Director shall publish a list of candidates who have passed the Semester Examination.

(ii) Each successful candidate shall receive a copy of the detailed marks card on having passed the Semester Examination.

12. The list of successful candidates after the Second semester examination shall be arranged as under in two divisions on the basis of the aggregate marks obtained in the first and second semester examinations taken together and the division obtained by the candidate will be stated in his certificate.

a) Those who obtain 50% marks but less than 60% marksSECOND DIVISION;

b) Those who obtain 60% or more marks -4


FIRST DIVISION;

c) Those who pass all the two semester examinations at the first attempt obtaining 75% or more marks in the aggregate shall be declared to have passed with - DISTINCTION

C. EVALUATION

13. (i) The Principal Director/ Course Coordinator of the Institute will preserve the records on the basis of which the, Internal Assessment awards have been prepared upto one month from the date of declaration of the semester examination results. This record will be disposed off after one month. The first Semester results must be declared before 20th of February of each year.

14. (i) The internal assessment/practical/workshop/training report/project report award of a candidate who fails in any semester/paper(s) shall be carried forward to the next examination.

(ii) Candidate(s) who has not obtained pass marks in the Internal Assessment in any paper(s) will not be allowed to take examination in the said paper(s) in the relevant semester. He/she will, however, be provided opportunity to appear before the Committee of Examiners, to be constituted by the Principal Director/ Director of the concerned Institute to re-assess performance of the candidate and the internal assessment given by the Committee shall be final.

(iii) A candidate who fails to obtain pass marks in training report/project report shall be offered opportunity to undergo training again and conduct another project as the case may be and the same shall be assessed by a board of examinations appointed by the Principal Director.

(iv) A candidate who fails to obtain pass marks in ROJT/practical/viva-voce shall have to re-appear before the board of examiners constituted by the PD/Director.

15. (i) The candidate shall be required to submit three copies of his Project Report. The last date for receipt of Project Report in the office of the Institute shall be one week before the commencement of the Second semester Examination.

In exceptional cases, the Director General may, on the recommendation of the Principal/Director of Institute, extend the last date of receipt of the project Report, till the commencement of the Second semester examination, with late fee.

(ii) The Project Report shall be evaluated as per the guidelines specified in the Scheme of Examination, jointly by the external and the internal examiners. The appointment of the external examiner shall be made by the Director General on the recommendation of the Principal Director of the respective institute.

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(iii) The marks obtained by the candidate for the project report shall be taken into account when he appears in any future examination under reappear clause.

16. (a) The comprehensive viva-voce/workshop shall be conducted by a Board of Examiners to be appointed by the Director General on the recommendation of the Principal Director/Director of the respective institute consisting of the following members:-

i) One Internal Faculty nominated by the Director of the concerned Institute;

ii) One or Two External Examiners from the Industry/Academic field

(b) The marks obtained by the candidate for the viva-voce/workshop shall be taken into account when he appears in any future examination under re-appear clause.

17. The Project Report and Training Report, wherever specified will be submitted in the typed form as per the following requirements:

(i) The typing should be done on both sides of the paper (instead of single side printing)

(ii) The font size should be 12 with Times Roman Format.(iii) The Project Report/Training Report may be typed in 1.5 (one and a

half) space. But the References/Bibliography should be typed in single space.

(iv) The paper should be A-4 size.(v) Two copies meant for the purpose of evaluation may be bound in

paper-back form and one copy should be in hard binding.(vi) Students will select topic of the project by 30th October of each year.

Course Coordinator will submit the consolidated list of project with name of students to the Principal Director/Director on first working day of November.

D PROMOTION AND REAPPEAR

18. The minimum percentage of marks to pass the examination in each semester shall be :-

a) 45% in each written paper and internal assessment separately;b) 45% in Training Report/Project Report and Viva-Voce separately.c) 50% in the total of each semester examination.d) A candidate who has secured minimum marks to pass in each paper but

has not secured the minimum marks required to pass in aggregate for the semester concerned may take re-examination (in not more than two papers) to obtain the aggregate percentage required to pass the semester.

19. A candidate whose result is declared late without any fault on his/her part, may attend classes for the next higher semester provisionally at his own risk

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and responsibility, subject to his/her passing the concerned semester examination. In case a candidate fails to pass the concerned semester examination, his/her attendance/internal assessment in the next higher semester in which he was allowed to attend classes provisionally will stand cancelled.

20. A candidate shall be promoted to the next higher semester if he/she passes at least 50% of the theoretical papers (i.e. excluding subjects in which marking is done on the basis of Viva Voce) having prescribed in the semester, failing which he/she shall be declared as FAIL in that semester and he/she shall be required to appear in the failed semester in all the papers currently in force as, a private candidate (as ex-student).

EXPLANATION : 50% of five papers will be taken as three and that of seven papers as four and that of nine papers as five under this Clause.

E. OTHER PROVISIONS

21. Question paper for the External exams will be common for all the institute and will be set by a faculty who will be paid honorarium of Rs. 2500/- per subject plus postage charges on actual basis. Question paper setting will be responsibility of one of the institute on rotation basis ie. New Delhi, Nagpur, Neyveli and Durgapur respectively. Question papers will be broadly subjective in nature.

22. Answer sheets of the Semester exams will not be evaluated in the parent institute and sent for outside evaluation. The evaluator will be paid an honorarium @ Rs. 40 per copy plus postage on actual basis. For evaluating the project report or conducting viva voce the external and the internal examiner will be paid honorarium of Rs. 40/- and Rs. 20/- respectively per student plus TA. Similarly faculty evaluating for simulator will be paid honorarium @ Rs. 20/- per student.

23. The invigilators in the semester exams will be paid a honorarium of Rs. 200/- per sitting of 3 hour. For 30 students one invigilator, for 30-60 students two invigilator and for more than 60 students 3 invigilators may be employed. Principal Director/ Director in-charge will act as Chief Superintendant of the examination and will be responsible for smooth conduct of examination and shall be paid a lump sum honorarium of Rs 2000/- for the semester final exams. A centre clerk and two peons (for sealing, water serving etc.) may be appointed by the Chief Supdt. for conduct of semester examination and may be paid an honorarium of Rs.120/- and Rs.50/- per sitting respectively. The centre clerk will assist the Chief Supdt. in making seat plan, maintenance of files (attendance, billing, dispatch of answer sheets etc.) for the exams.

24. Tabulation of the internal and external marks will be done by a faculty and shall be paid honorarium @ Rs. 20 per student. He will be responsible for collecting all the marks and tabulation and publication of the final result. The Principal Director /Director Incharge will nominate the tabulator of their respective institute. The tabulation records of the passed out students will be kept with Training Officer/Course Coordinator of the respective institutes.

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25. A sumptuary allowance of Rs.1000/- per month may be granted to the course coordinator of PGDC in TPPE at the respective institutes and this expenditure will be met from the examination fee collection. The Course Coordinator will maintain the records of registration, feedback (to be taken once in each semester) and will prepare the day wise module of the course and intimate the faculty for their lectures.

26. Instruction For The Question Paper Setter: The question setter will set two sets of question paper for each subject and mark on the envelop Set A and Set B and seal them separately. The sealed Envelops For Set A and Set B should be sealed in a bigger envelop and sent to the respective principal director. The Paper setter should maintain the confidentiality of the question paper and all rough worksheets should be destroyed. The question should be broadly subjective in nature and should cover all parts of the syllabus. The maximum marks for each subject is 100 and pass marks is 45. The time allowed for each paper will be 3 hours. The subject syllabus can be identified by the following help:

Power Plant Familiarisation I: This includes the General Introduction module, Industrial Safety module and 5th and 6th week module of Power Plant Familiarisation.

Power Plant Familiarisation II: This includes 1st to 4th week module of Power Plant Familiarisation

All other subjects have nomenclature pertaining to the modules which have been included.

27. The corporate quality committee will meet every year in the last week of July to review the status of the course.

28.Any other provision not contained in the above shall be governed by the rules and regulations framed by NPTI from time to time.

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FIRST

SEMESTER

PGDC IN TPPE

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Module : General Introduction(Duration): ½ week

FORENOON AFTERNOON

DAY-1 Registration and Inauguration , CourseDescription, Institute facilities

Growth of power Industry after Independence

DAY-2 Site Selection (Site availability, Raw material, Fuel, load evacuation, Water, Transport, Pit Head Station ,Air Pollution, Topography, Skilled manpower ).

Coal to Electricity (Coal /Air / Flue/ Gas/ Water / Steam Path ,Brief description of main equipments involved in a Thermal Power plant Station )

DAY-3 General layout of a Thermal Power Station (Block Diagram of main equipments, Generator and their Auxiliaries)

Visit to Thermal Power Station

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Module : Industrial Safety(Duration): ½ week

FORENOON AFTERNOON

DAY-1 Accidents (Causes & Factors, Cost of Accidents , Accidents Prevention, Investigation of Accidents, Reporting and Recording Systems of Accidents)

First Aid (Basics of First Aid, How injuries are caused in lifting, falls etc.)

DAY-2 Fire fighting (Fundamentals of Fire, Fire Fighting Equipments and systems, Fire Extinguishing Methods, Demonstration of various fire.)

Industrial Safety & hazards(Industrial Hazards ,Protective Clothing and Equipment, Safe work practices in power Plants, permit to work system, safety in moving and storage of materials, Housekeeping Safety rules)

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Module : Power Plant Familiarization

(Duration): 6 week

FORENOON AFTERNOON

DAY-1 Steam Cycle Theory (Carnot cycle , Rankine cycle, with reference to a specific unit 500/210 MW , steam properties)

Coal (Types of coal and their characteristics, Their suitability for different kinds of Boiler, Alterations in firing methods due to change of coal composition)

DAY-2 Coal Handling system (Location and layout, Main Equipments and their functions , Coal transportation , preparation, storage and reclamation , MGR system, safety aspects , Fire prevention and fire fighting in coal handing plant )

Combustion Theory(Definition , Combustion requirements, factor influencing combustion, combustion of fuels , gross and net calorific value)

DAY-3 Fuel Oil Systems (Location and site selection, Type of fuel used , Main equipment and their functions Transportation, handling , storage Fuel oil preparation before firing)

Plant visit (visit to coal handling plant, visit to fuel oil station)

DAY-4 Description of Main Boiler (Classification and Types, Arrangements of main boiler , Fundamentals of Boiler design , Location of various pressure parts)

Boiler Circulation Theory (water walls boiling phenomena , Nucleate / Film boiling , Natural / Controlled / Forced circulation )

DAY-5 Constructional detail of Super heaters, Re heaters, Economizers, De super heaters.

Steam Separation theory ( Boiler Drum & its internals)

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Module : Power Plant Familiarization(Duration): 6 week

2 ND WEEK

FORENOON AFTERNOON

DAY-1 Audio-visual / CBT Session on Drum and Drum internals

Draught system (Theory of natural, induce, balance and forced draught , Drought loss stack effect)

DAY-2 Various Fans and their salient features (Construction detail / lubricating oil system for PA fan, FD, ID fan)

Air Pre heaters(Types And Functions Constructional Details, SCAPH. Soot Blowers.)

DAY-3 Ventilation and Air conditioning Pulverizes and Feeders (Classification Of Mills ,Constructional features of Bowl mill Pulverization of Coal, factors affecting Milling Plant Performance, Coal feeders and its type)

DAY-4 Fuel Firing Arrangements and Burners (corner front and rear wall firing , Direct and indirect , Details of coal and oil burners Burners tilting Mechanism , Atomization of fuel oil burners and igniters )

Electrostatic Precipitator (ESP) (Need of fly ash separation, working principle , corona effect, constructional details, Rapping mechanism)

DAY-5 Ash Handling System (Fly ash handling system, Bottom ash disposal system , Ash handling plant operation ,Ash handling pump, Disposal of ash slurry ,utilization of ash)

Plant visit (Milling plant, Main Boiler and Fans, Ash handling).

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Module : Power Plant Familiarization(Duration): 6 week

3RDWEEK

FORENOON AFTERNOON

DAY-1 Furnace, Safeguard, supervisory System

(Description of field equipments (no C&I )

Audio Visual Session (FSSS)

DAY-2 Water Supply System (soft water, clarified water, cooling water, D. M water)

Steam Turbines (Classification of Turbines Metallurgical considerations, Working Principles

DAY-3 Description of main components i.e. Turbine casing, rotor steam admission valves, couplings , bearings etc.

Turbine lubrication Oil System Construction and working Principles of main Oil pumps , Oil coolers)

DAY-4 Steam condensation and Condensers(film wise/drop wise condensation, Direct/ indirect condensation and vacuum creation)

Audio-visual (vacuum System, Turbine lubrication Systems

DAY-5 Power Station Pumps (Classification of pumps, Centrifugal pumps, positive displacement pumps)

Boiler Feed Pump (Function of BFP Constructional details)

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Module : Power Plant Familiarization (Duration): 6 Weeks

4TH WEEKFORENOON AFTERNOON

DAY - 1 . Circulating Water System (Open/ Closed system, CW Pumps, Cooling Towers, CT Pumps, CT Fans)

Plan Visit (CW System including Cooling Towers, CT Pumps, CT Fans, Condenser Vacuum Ejectors, BFP)

DAY - 2 Regenerative Feed Heating System (Working Principle and constructional details of L.P. Heaters, Deaerators, H.P. Heaters GSC, Ejector)

Visit to (Regenerating Feed Heating System, Turbine Lubricating Oil system, Water Treatment Plant)

DAY - 3 Turbine Governing System ( Types of Governing systems. Various components, systems and their functions, Oil circuit for Governing System. Overall working of governing system with reference to load throw off. Load raising).

Turbine Governing System (Contd.)

DAY - 4 Audio/Visual Session on GoverningSystem.

HP/LP Bypass system and PRDS and its utility, Various interlocks and protections

DAY – 5 Audio/Visual Session on HP/LP By pass System.

Plant visit (Governing System and HP/LP By pass System).

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Module : Power Plant Familiarization(Duration) : 6 Weeks


DAY - 1 Generator Constructional Details (Basic principle of electricity, generation Development of generator design, Construction details of rotor, stator etc.

Tutorial/General discussion.

DAY - 2 Hydrogen Cooling System and Stator Water Cooling System (Different types of cooling arrangements for rotor and stator, Selection and properties of coolant, Air cooling, Hydrogen cooling, Stator water cooling, H2 Charging/ Purging Cycle).

Audio visual on Hydrogen cooling system

DAY - 3 Hydrogen Seal Oil System (Details of the system, Function and purpose of differential pressure regulator and pressure oil regulators, Types of Hydrogen seals and their construction details).

Generator Excitation System and AVR (Principles, Simple arrangem- nts of excitor and its field winding, Classification of excitation system - High Frequency / static excitation system - their merits and demerits, Automatic Voltage Regulator).

DAY - 4 Audio/Visual Session on ExcitationSystem.

Plant Visit (Generator and Auxiliaries, Hydrogen cooling & Stator Water Cooling System, Hydrogen Seal oil system).

DAY – 5 Transformers (Working Principles, Various types of transformers used in a power station, Constructional features of main transformer and accessories, Bucholtz relay and main protections, Types of cooling, Mulsifire and other fire protection systems.

Audio/Visual/Discussion session.

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Module : Power Plant Familiarization(Duration) : 6 Weeks


DAY - 1 Motors (Fundamentals, Constructional details of HT/LT Motors, Various motors used .in Power Stations.

Plant visit (Transformers Excitation System)

DAY - 2 HT-LT Supply system/DC Supply System (A typical layout of 6.6 KV, 3.3 KV and 415 V supply system in a TPS, DC Supply system in a TPS .

Audio visual on electrical System.

DAY - 3 Switchyard (A typical layout of Switchyard of a Thermal Power Station, Bus system, Isolators, CTs, PTs, Earthing, Oil Circuit Breakers, Air Blast Circuit Breakers. SF6 Circuit Breakers).

Plant Visit (Switchyard, HT/LT System, DC Supply System).

DAY - 4 Audio/Visual Session Discussion

DAY – 5 Written Appraisal.

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Module : Scheme Briefing & Tracing(Duration) : 2 Weeks

1ST WEEK

FORENOON AFTERNOONDAY - 1 Scheme briefing in class room on

Boiler Drum connections, Feed regenerating Heating System, Air and Flue Gas Path.

Class Room briefing on Fuel oil system and milling system.

DAY - 2 Class Room briefing on Main steam. Cold reheat, Hot reheat lines, condensate & feed water lines, BFP, CW schemes.

Class Room briefing on Hydrogen cooling, stator water cooling, seal oil system, switchyard, AC/DC auxiliary power supply system,

DAY - 3 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. pipe line layout with provisions for expansion.).

DAY - 4 Boiler - Feed Water Schemes (Feed control station arrangement, economiser connections, economiser recirculation lines, boiler drum, water wall connections; drain header, blow down lines, CBD, IBD, SH/RH, attemperator station).

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).

DAY – 5 Air and Flue Gas Schemes (ID,FD, PA fans and their control system including Seal air/ Scanner air/ Igniter air Fans/Systems/ Damper control for secondary air.

Fuel Schemes (Scheme of RC bunkers and RC feeders, Coal mill connections. Light oil and. atomising air system, location of trip valves, air control valves, nozzles valves and igniters. Heavy oil and atomising steam system).

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Module : Scheme Briefing & Tracing(Duration) : 2 Weeks

2ND WEEKFORENOON AFTERNOON

DAY - 1 Water Treatment Plant (Raw water tanks to DM Water storage tanks, arrangement of Pressure sand/Activated carbon filters, cation, anion, mixed beds, degassifier, back washing system, regeneration, Phosphate and Hydrazine dozing scheme.

Ash Handling System - Bottom Ash and Fly ash disposal system – hoppers/Clink grinder, HP/LP water injection, Ash slurry pumps etc.

DAY - 2 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 heater, deaerator connections. Scheme of Feed Water flow, BFP connections, Feed water connections to HP heaters, Location of valves, interconnections, by pass arrangement for heaters)

DAY - 3 Turbine Oil System (Turbine lube oil schemes, lube oil purification schemes, location of MOT & lube oil pumps, Oil coolers, cooling water connections.

CW System and Cooling Towers (locating moving screens, CW Pumps, Venting arrangements, Valve locations, Chlorination schemes).

DAY - 4 Generator (Seal oil scheme, Hydrogen scheme, Stator water cooling schemes, Excitation arrangements).

Switchyard (GT to feeder line arrangements, locating various transformers (GT, UA SAT, CTO, PTO), switchgears, isolator earthing arrangement, buses etc

DAY – 5 Auxiliary Power Supply (6.6 KV schemes/ 420 V Schemes, arrangement of breakers, buses. DC system, battery bank arrangement).

Viva-voce.

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Module : Power Plant Operation(Duration) : 2 Weeks

1ST WEEK

FORENOON AFTERNOONDAY - 1 Availability of electrical supply to

the equipment (source feeder of each equipment, points of the isolation of the equipment, locking during isolation, permit to work system).

Boiler pre light up checks. (Meaning of line up, shut down, tripping, starting etc. no pending permits, Local checks.)

DAY - 2 Operation of service auxiliaries (cooling water pump, compressors, auxiliary steam, fuel oil pumps.

Operation of air-pre heater and ID fans, pre checks, flow path line up, permissive interlocks.

DAY - 3 Operation of FD & PA Fans (Pre checks, flow path line up, permissives, interlocks).

Mill operation (Pre checks, flow path line up, permissives. interlocks).

DAY - 4 FSSS (Secondary air, burner tilt, fuel and air control).

Drum level control, Super heater/ Re-heater temperature control and their interlocks.

DAY – 5 Operation of turbine lub oil system and barring gear.

Operation of condensate and feed water system (BFP Heaters, CEP).

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Module : Power Plant Operation(Duration): 2 Weeks


DAY - 1 HP/LP Bypass operation and turbine heating.

Turbine rolling and synchronisation.

DAY - 2 Operation of generator cooling system (stator and hydrogen cooling).

Operation of Generator Excitation System, AVR.

DAY - 3 Operation of turbine governing system. Integrated operation of unit (unit loading and shut down sequence).

DAY - 4 Operational difference between Cold start up, Warm start up and Hot start up.

Load dispatching and coordination with load dispatch centre.

DAY – 5 Power Plant Emergencies (Boiler & Turbine).

Discussion and appraisal.

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Module : ROJ (OPERATION)(Duration): 5 Weeks

1ST WEEKFORENOON AFTERNOON

DAY - 1 Working with Boiler Firing floor Operator : (Cleaning of oil guns/Filters and their trial run, Checking feed control valves, blow down valves, air vents, coal feeders, secondary air dampers, ash level in economisers hoppers, Operation of Blow downs, chemical dosing valves operation, Charging of drum gauge glass aux. steam for soot blowing).

Continue.....

DAY - 2 Working with Coal Mill Operator (Shift taking over/handing over checks, Pre start checks, Routine checks, Mechanical Isolation of mills, Cold and hot air damper operation, Activities during emergency in mill area, Changing over of seal air filter, Oil filling into mill gear box)..

Continue .....

DAY - 3 Working with. Ash. Disposal operator (Checking for Shift taking over/handing over, Routine check (Note atleast one reading), Ash flow rate in full load and partial load unit operation (from Bottom ash and ESP Hoppers etc., ESP field electrical system, Isolation and charging of ESP fields, Ash disposal urn Color of Ash

Continue .....

DAY - 4 Working with Boiler Fans Operator (Checking -for shift taking over and handing over, Routine checks (Note: atleast one reading), Isolation of ID,FD,PA fans, Charging of lube Oil system, Change over of lube oil pump)

Continue .....

DAY – 5 Working with Compressor Operator (Shift handing over/taking over checks, Routine checks (Note: atleast one reading), Charging of Drier, Regeneration of Drier, Starting and stopping procedure. Emergency operation.

Continue .....

Note:- The students shall Undertake the 'Rotational On-job Training (Oprn)’,in the Power Station identified by the concerned NPTI. The course Co-ordinator shall make the appropriate shift roaster suiting to local conditions/shift roaster of the power plant.

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Module : ROJ (OPERATION) (Duration) : 5 Weeks


DAY – 6 Working with Boiler side supervisor (Shift taking over/handing over checks,Coordination with local operators, Reporting to Control Room,. Routine checks (Note: atleast one reading).

Continue .....

DAY – 7 Working with Boiler Control Desk Operator (Shift handing/taking over checks, Receiving site report from operators and supervisor concern, Logging of parameter (Note: atleast one reading), Operation procedure of different equipment

Continue .....

DAY – 8 Working with Boiler Control Desk Operator (Shift handing/taking over checks, Receiving, site report from operators and supervisor concern Logging of Parameter (note: atleast one reading), Operation procedure of different equipment.

Continue .....

DAY – 9 Working with CEP Operator (Shift handing over and taking over, Routine checks, Chemical dosing pump, starting procedure and making of chemical solution, Checking of make up and other controller, Priming of water box, Start of ejectors, Charging of LP Heat

Continue .....

DAY – 10 Working with BFP Operator (Shift handing over and taking over, Routine checks (Note: atleast one reading), Precheck for starting BFP, Charging of lub oil system, Change over of filters, checking of control v/vs., Operation of Recirculation valves, Charging Isolation of HP Heaters, Deaerator water heating, Aux.. steam charging/isolation) Valve

Continue .....

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3RD WEEK FORENOON AFTERNOON

DAY – 11 Working with Turbine Operator (Shift handing over & taking over, Routine checks (Note: one reading), rechecks for starting lub oil system, Filling of oil in Main Oil Tank, AC, DC, Jacking oil pump checks, Instrumentation fitted with main oil tank, Parameters of Governing system, Charging and isolation of governing system, ESV, IVs and control V/Vs, local operation, HP/LP By pass

Continue .....

DAY - 12 Working with Generator Operator ( Shift handing and taking over, Routine checks, Pre start checking of seal oil, Hydrogen cooling, Stator water cooling system, Purging of H2 and C02 of Hydrogen cylinder charging, Cooler/Filter charging.Working with Turbine Supervisor (Shift handing/taking over, Routine checks by supervisor, Coordination with Operator, Reporting to Control Room)

Continue .....

DAY - 13 Working with Turbine Desk Operator (Shift handing over & taking over, Receiving report from supervisors and operators, .Logging of parameters, Operation Procedure of main equipment, ATT & ATRS operation, Emergency operation).

Continue .....

DAY - 14 Working with Electrician/Supervisor (Shift handing over and taking over, Routine check of Diesel set and other parameter, HT & LT Breaker Isolation and normalisation procedure, Charging of DC Batteries, Checking of GT, U AT and service transfolll1ers, Safety devices, Operation of switchgear compressor).

Continue .....

DAY – 15 Working with Electrical Desk Engineer (Shift handing over/taking over checks, Routine check (Note one reading), Operation procedure of various equipment at generator desk like excitation s stem. AVR etc).

Continue .....

24



4TH WEEK FORENOON AFTERNOON

DAY – 16 Working with Hydrogen Plant Operator (Shift handing / taking over, Operation of H2 Plant, Filling operation of H2 cylinder, Analysis of H2and O2 concentration. Routine checks).

Continue .....

DAY - 17 Working Coal handling control room (Shift handing/taking over, Pre-checks of CRP equipment operation, Operation of Crusher, belt conveyor, tripper, flap gate, Unloading procedure of wagons, Magnetic separator and weighing arrangement, Routine checks, Bunker filling and level monitoring, Coordination with mines, unit incharge and shift incharge, Coal amt. recording,Reclaimer).

Continue .....

DAY – 18 Working with Switchyard Control Room Engineer (Shift handover/takeover, Routine check, Load schedule for the month, week and day, Load sharing by Units, Charging/isolation of HT Bus, Reporting to in house and external agencies about load schedule. operation of Isolators and brokers).

Continue .....

DAY – 19 Working with Cooling tower and cooling water pump operator (Shift handing over/taking over, Routine checks, Pre-start checks of CT and CW Systems, Starting/Isolation of cooling towers, CT .' Pumps, CW Pumps, Emergency operation, Lub oil system of C\V and CT Pumps.

Continue .....

DAY – 20 Working with Performance Monitoring Cell (Collection of information from each section, Programme for calculation (show at least one day calculation of all parameter), Analysis of result and comments preparation, Daily plant meeting (input and output),Reporting to concern about plant performance).

Continue .....

25


Module : ROJ (OPERATION)(Duration) : 5 Weeks


DAY - 21 Working with Shift chemist (Shift handing over / taking over, Routine activities, Collection of samples of (Coal:-oil, H2, Drum Water, Steam Condensate etc.) (note down pt. of sampling), Analysis of sample (Note down the value), Action suggested to bring the concentration normal.

Continue .....

DAY – 22 Working with DM Plant chemist (Shift handing over and taking over, Routine checks, Storage tank. for clarified and DM water, Starting and Isolation of DM Water pump Regeneration of Ion Exchange

Continue .....

DAY - 23 Working with Unit Incharge (Shift hand over/take over, Investigation and reporting of plant defects and abnormalities. Issue and canceling of PTW, Hot and Cold startup of unit, Decision during emergency, coordination and reporting of problem to higher Management, Main parameters, monitored (take one reading).

Continue .....

DAY - 24 Working with Shift Incharge (Shift handing over / take over, Receiving report from unit Incharge, Instruction to SCE regarding load sharing, Reporting to higher management, Main parameters monitored (take onereading).

Continue .....

DAY – 25 Working with Air-conditioning Operator (Shift hand over/take over. Routine checks (take one reading). Temperature Control, Humidity Control, Operation of AC Plant, Dust Control).

Apprasial/Disussions

26


Module : Erection, Commissioning & Construction Management

(Duration) : 2 WeeksErection, Commissioning

1st WeekFORENOON AFTERNOON

DAY - 1 Preparation of commissioning, trial run of various equipments, commissioning of valves, air and gas tightness test of boiler.

Chemical cleaning of Boiler preparation for boiler light up, thermal flow test of water walls and economisers, steam blowing.

DAY - 2 Safety Valve setting, reliable run of boiler, Hydraulic test of boiler.

Alkaline flushing and commissioning regenerative system, acid cleaning of oil pipe lines, oil flushing procedure of lubricating oil and governing, system.

DAY - 3 Turbine Lubricating oil flow testing, steam blowing, reheater safety Valve setting, vacuum tightness test ejector testing.

Commissioning of governing system ATRS & ATT, and TSE.

DAY - 4 Commissioning of generator and auxiliaries (Generator testing, rotor and stator cooling system, excitation system

Commissioning of electrical system (Circuit breakers, isolators, CT and PT, rectifiers, switchgear DC system).

DAY – 5 C&I Commissioning activities (Minimum instrumentation s required for major C&I commissioning, commissioning of control of valve, tuning of control valves).

Discussion/Appraisal

27


Module : Erection, Commissioning & Construction Management

(Duration) : 2 WeekConstruction Management

2nd WeekFORENOON AFTERNOON

DAY - 1 Construction, Site Organisation and Administration Estimating, Costing and Bidding

Construction Contracts & Contracting Construction Materials and Construction Project Management Techniques

DAY - 2 Tendering, Bidding, Contract Laws & Claims Management Risk Management Project Risk Management

Construction site Personnel Management Manpower Planning

Techniques Labour Laws for Construction

DAY - 3 Site Management, Construction Finance Management, and Cost Accounting

Materials and Logistics Management, Project Management

DAY - 4 Introduction to Construction Safety, Common Safety Hazards, Laws on Construction Safety, Health and Welfare, Safety Practices and Standards

Introduction to Equipment and Machines used in power plant construction, Planning and Selection, Case Studies on Construction EquipmentPlanning and Selection

DAY – 5 Construction Equipment Maintenance,Case Studies on Construction Equipment Maintenance

Management Information Systems in construction management, Construction Quality Management,Productivity, Safety and Quality

28


Module : Power Plant Performance and Efficiency Calculation

(Duration) : 1 Week

FORENOON AFTERNOONDAY - 1 Introduction, Need for performance

monitoring, objective, controllable and un-controllable factors, basic requirements.

Factors influencing performance of Boilers and Optimisation (Fuel properties, excess air, fineness of PF etc.)

DAY - 2 Performance Monitoring of Boiler Auxiliaries (Pulverisers, Factors, sampling of pulverised coal, classifier adjustments, mill rejects, causes and remedies) Air Heaters (effect of AH outlet temperature, Performance tests) Fans (Performance, curves, optimum operation point.)

Boiler efficiency calculation (Direct method calculation, limitations in adopting direct method, (Losses method, Other standard method.)

DAY - 3 Factors influencing performance of turbine( Steam pressure, temperature and Back pressure, cylinder efficiency, deposits on turbine blades, blade roughness, effect of tubes) 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 attemperation in reheaters). Heat balancing.

DAY - 4 Turbine heat rate calculations (Method parameters required).

Optimisation of auxiliary power consumption (Scope, variable speed drives, operation of un-necessary running auxiliaries).

DAY – 5 Logging and recording (Scope of logging and recording, use of DAS/DDC in performance monitoring).

Discussion and appraisal.

29


Module : Power Plant Chemistry ,Metallurgy, NDT and WeldingDuration : 2 Week

Chemistry

1/2 Week FORENOON AFTERNOON

DAY - 1 Basic chemistry (Atomic structure, elements, compounds, mixtures, solutions, ionization, salts acids alkali pH values).

Pre and post treatment of water.

DAY - 2 Chemical control and treatment of Boiler feed water and steam. Cooling water treatment

Classification of coal & oil, their sampling and analysis

DAY - 3 Corrosion theory and deposition

30


Module : Power Plant Chemistry ,Metallurgy, NDT and WeldingDuration : 2 Week

Metallurgy 1 Week

FORENOON AFTERNOONDAY - 1 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.

DAY - 2 Steel – making - Microstructure Composition/property relationship of steel - effects of - alloying - power plant steels.

Heat treatment and surface hardening of steel failure mechanism - typical such situations in a power plant.

DAY - 3 Non-ferrous metals and alloy's: Application of Non ferrous metals and alloys in PP condenser components - conductors slot wedges in generator rotor - pipe to pipe couplings - bearings. Copper, Aluminum, Nickel, Magnesium. Titanium and their alloys in properties of theses alloys failure mechanism.

Non metallic materials : Use of plastics and rubber in PP – Thermoplastics – thermo sets rubbers their properties. Application, coatings, adhesive, linings, insulation seals, sealants, gaskets etc. Application of ceramics in Power Plant – Insulation Refractory properties.

DAY - 4 Material selection for Design Material requirement, specification and relevant standards fro boiler, turbine, generator components – Piping and Valves : Appreciation of component, fabrication – metal forming, casting – forging, pipe bending, tube manufacture.

Protective surface treatment. (Metal cleaning protective Metal coating, Fabrication of precoated metals).

DAY – 5 Defect analysis and life assessment. Low temperature behavior. high temperaturebehavior - defect assessment of solidification crack austenite stainless steel welds, cracking in CrMoV 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.

Group discussion and appraisal

31


Module : Power Plant Chemistry ,Metallurgy, NDT and Welding Duration : 2 Week NDT & WELDING

1/2 WeekFORENOON AFTERNOON

DAY - 1 Introduction to welding and types of welding.

Description of welding methods generally used in thermal power station.

DAY - 2 Welding machines, types of electrodes, precautions during welding process, welding defects.

Purpose of NDT and types of defects cover by NDT.

DAY - 3 NDT Methods used in power station (Principle, equipments, utilization, merits and de-merits).

32


Module : Gas turbine & combined cycle power plant(Duration) : 1 Week

1st week

FORENOON AFTERNOONDAY - 1 Gas Turbine and Combined cycle

power plant-introduction, basic cycles and types of CCGT

Fuels for gas turbine plants, physical and chemical properties of fuels and their analyses

DAY - 2 Description and construction details of CompressorsDescription and construction details of Combustors

Gas turbine construction details- blade materials and its selection, cooling arrangement

DAY - 3 Gas turbine support system, inlet / exhaust systems, lube oil system, fire protection system, governing system

Waste heat recovery steam generator - Description and construction details. Cogeneration plants.

DAY - 4 Emission control –main emission products, its effects and control.

Operation of Gas Turbine and CCGT plant- Pre checks, Startup and shutting down procedure including normal operation.

DAY – 5 Efficiency and performance monitoring, optimization of CCGT, performance testing.

Combined cycle power plant maintenance- planning for schedule maintenance, various checks, case study.

33


Module : Advanced Steam Generation Technology- Supercritical and FBC

(Duration) : 1 Week

FORENOON AFTERNOONDAY - 1 Introduction to supercritical

technology, advantages-World scenario in supercritical technology.

Arrangement of super critical boilers and their types. Comparison between spiral water wall circulating and vertical tubing.

DAY - 2 Special alloys for super critical boilers and welding techniques.

Differences between Supercritical and subcritical Technology

DAY - 3 Introduction to FBC Technology Advantages, Scope, Fuel flexibility etc

Classification of FBC technology boilers.

DAY - 4 Description of various components of CFBC Boiler

Environmental benefits

DAY – 5 Limitations, major concerns in the O&M of FBC Boilers

Visit to Supercritical/FBC Boilers

.

.

.

34


Module : Business Communication & Personality Development (Duration) : 1 Weeks

1ST WEEK

FORENOON AFTERNOONDAY - 1 Presentation Skills: Perquisites of

effective presentation, Format of presentation

Assertiveness, Indicators of assertive behaviour, Strategies of assertive behaviour

DAY - 2 Communication skills for Group Discussion and Interviews

Business Etiquettes: Business dining, business manners of people of different cultures

DAY - 3 Non verbal communication: gestures, handshakes, glazes, smiles, hand movements, style of working,

Non verbal communication: Continued…..voice modulation, Body sport for interviews,

DAY - 4 Written Communication: Mechanics of writing , report writing, circulars, notices, memos, agenda and minutes

Written Communication contd…….Business correspondence, business letter format, style of letter arrangement, types of letters,

DAY – 5 Written Communication contd……..Telex messages, facsimile, electronic mail, Developing Resumes

Viva Voce

35


SECOND

SEMESTER

PGDC IN TPPE

36


Module : Power Plant Protection (Duration) : 1 Week

FORENOON AFTERNOONDAY - 1 Introduction (Terminology,

Requirements of protective system, Historical developments) Protective Relays (Types and their applications, Construction, Maintenance requirements, Setting and testing).

Methods of system earthing and the fault conditions, Lighting / Surge Instrument transformers.

DAY - 2 General Protection (Neutral earthing. Stator and rotor earth faults, Sustained external faults, Instability, Protective systems used above).

Transformer Protection (Various protections, Protective systems for Transformers, UATs & STs).

DAY - 3 Motors (Faults and protection systems).

Automatic Voltage (Requirements, types and function mechanical, electronic amplifier magnetic amplifier regulators, construction, maintenance and testing).

DAY - 4 Bus bar Protection (Continuity of supply, Discrimination, Circulating current systems, Special features relating to different voltage - Pilot wire, carrier current, systems). protection, PLCC TeleCommunication).

Feeder Protection (Continuity of discrimination, Outline of Pilot wire, carrier current, protection, PLCC – Tele communication).

DAY – 5 Visit to Power Station and Lab. demonstration.

Group discussion and appraisal.

37


Module : Energy Audit(Duration): ½ week

FORENOON AFTERNOON

DAY-1 Need for Energy Audit and Audit Procedures. Energy Audit – Macro Level & Micro Level.

Energy Management System, Energy Auditing and their implementation techniques for power industries.

DAY-2 Energy Saving methods with typical examples and exercises for power stations

Ways to minimize losses in power transmission & distribution system

DAY-3 Energy Losses – An Integrated optimal strategy for reduction of T&D Losses.

38


Module : Maintenance Planning & Cost Control

(Duration) : 1 Week

FORENOON AFTERNOONDAY - 1 Aims and objective of maintenance

efficient service, high plant availability, maintenance learning engineer's duties.

Integration of maintenance with requirements, plant reliability, plant and daily work programs.

DAY - 2 Preventive maintenance of running units.

Planning of major plant overhauls shutdowns.

DAY - 3 Planning techniques – critical path analysis, charting system etc.

Purchasing and stores control- standards, cost codes. Control of stores and store records.

DAY - 4 Cost control. Direct costs, indirect costs, outage costs, budgeting and costing work, budgetary control.

Contract procedures (Conditions of contract, capital applications and procedure, project evaluation, interest and depreciation charges).

DAY – 5 Role and application of Information Technology in maintenance planning.

Group discussion and Appraisal

39


Module : Nuclear Power Plant Familiarization (Duration) : 1 Weeks

1ST WEEK

FORENOON AFTERNOONDAY - 1 Introduction of nuclear energy, energy

from nuclear fusion, plasma, energy from nuclear fission

The fission process and fission products, radioactivity, radioactive materials

DAY - 2 Regulation for governing the production of power from nuclear fuel & safety aspect. National policy regarding Nuclear power generation.

Nuclear reactor and power plant- Reactor, general components of nuclear reactor.

DAY - 3 Pressurized water reactor (PWR), boiling water reactors (BWR) & Canadian deuterium uranium reactor (CANDU)-mass and heat balance, working principle and construction details

Gas-cooled reactor, liquid metal cooled reactor - mass and heat balance, working principle and construction details, material for Gas-cooled reactor, liquid metal cooled reactor, advantages and limitation. Sodium–graphite reactor SGR, fast reactors.

DAY - 4 Organic cooled and moderator’s reactor, Breeder reactors working principle and construction details, material for reactor

Nuclear materials-nuclear fuel, coolant, moderating and reflecting materials, shielding materials.

DAY – 5 Nuclear waste & its disposal-types of nuclear waste ,effect of nuclear radiation

Appraisal

40


Module : Renewable Energy and Hydro Power Plants

(Duration) : 1 Week

FORENOON AFTERNOONDAY - 1 Energy Sector Reforms, Regulations

Environment and REWind Energy Systems

DAY - 2 Solar thermal power systems Direct energy Conversation - Solar Photovoltaic, Fuel Cells.

DAY - 3 Biomass Energy Systems. Introduction of small, mini and hydro power generations

DAY - 4 Basic features of hydro Turbines Hydrology and estimation of water potential

DAY – 5 Site selection and Layout of Hydro power plants

Description of Hydro Turbine Interlocks and protection

41


Module : Maintenance Practice & Inspection(Duration) : 4Weeks

1ST WEEK

FORENOON AFTERNOONDAY - 1 Checking of Boiler tubes for external

damage due to erosion or cutting. Method to overcome, e.g. strengthening of tubes in the flow channels.

Hydraulic test, allowable rate of pressure drop. Checking of welds pin holes.

DAY - 2 External cleaning of boiler surface and water washing. Use of sky climber, Different types of tube failures creep overheating

Measurement of tube wall thickness, Checking of flue gas path for direct corrosion or erosion and leakage.

DAY - 3 Checking of isolating and regulating dampers for leakage, proper alignment, adjustment for both under cold and hot operation conditions.

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

DAY - 4 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

DAY – 5 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 also Ball ring segment wear. Keeping of capacity and hour of operation. Check roller thrust bearings and ring, seals

42


Module : Maintenance Practice & Inspection

(Duration): 4Weeks 2ND WEEK

FORENOON AFTERNOONDAY - 1 Check the adjustment of roller of ball

pressure check for leakage of coal and air around journal assembly main shaft and possible contamination of lubricating oil method for reservation

Check the gear-box worm and worm wheel driver for wear and backlash allowable limits. Check classifier vane angular position proper operation and coal fineness

DAY - 2 Air heater maintenance/trouble shooting causes and remedies

Soot Blowers Maintenance/Trouble shooting causes and remedies

DAY - 3 Safety valve maintenance and its float procedures, trouble shooting/causes remedies

Procedure for alkali boil out and acid cleaning preservation and flushing, Procedure for flushing and preservation both wet and dry

DAY - 4 Internal checking of drum and drum internals, Checking of at temperature including spray nozzle and shock linen

Boiler bottom air seal, proper and free movement and expansion of boiler setting when hot. Normal water level and flow in bottom seal. Adjustment and prevention of dust accumulation in the seal chamber

DAY – 5 Maintenance of clinker grinder, bottom ash hoppers maintenance of De-watering pump slurry pumps and slurry line

Furnace tightness checking, Bench mark for draught loss for different gas flow

43


Module : Maintenance Practice & Inspection

(Duration) : 4Weeks 3RD WEEK

FORENOON AFTERNOONDAY - 1 Checking of tubes for any obstruction

land test or temperature rise and drop test.

Procedure of welding of tubes in membrane walls and tubes of different composition

DAY - 2 Mechanical portion of governing system and its maintenance

Checking of over speed ring and eccentricity pick up for correct operation.

DAY - 3 Checking of turbovisory instrument particularly total expansion and differential expansion

Turbine rotor and blade maintenance and inspection checks, Checking of turbine cylinders for cracks deformation.

DAY - 4 Checking the rotor position with respect to clearance in HP IP and LP wheel clearance and also thrust bearing and its wear. Checking the condition of babbit metal for scoring pitting, chipping of or lack of bondage between the babbit and the shell.

Main oil pump cleaning/flushing of main oil tank, pipes, cleaning of filters oil coolers, mtce. , of jacking oil pumps.

DAY – 5 Overhauling of control valves, ESVs and IVs, Maintenance and inspection of oil system turbine oil coolers, Maintenance of condensate side and steam side tubes

Condenser tube maintenance, off lead and off load cleaning procedure

44


Module : Maintenance Practice & Inspection(Duration): 4Weeks

4TH WEEK

FORENOON AFTERNOONDAY - 1 Maintenance of main ejectors and

starting ejectors Trouble shooting causes remedies, Checking of axial shift indicating system for Clean oil nozzle and strainers.

Checking of bearing clearances and allowable limits. Checking of cylinders parting surface, for proper matching, its grinding for the purpose.

DAY - 2 Checking of gland and seal strips, their clearances with allowing limits.

Checking the coupling alignment of HP IP and LP rotors and generator and their. Setting. Checking and setting of bearings on foundation. Checking of shaft sinking due to I vacuum pulling.

DAY - 3 Generator Maintenance : A Stator - Checking 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.

DAY - 4 Transformer maintenance - insulation testing drying out routine maintenance.

HT Switchgear testing - routine and type tests.

DAY – 5 Motor Insulation checking, terminal checking, phasing out. motor drying.

Cable jointing, material and techniques

45


Module : Design Analysis(Duration): 1 week

1st WEEK

FORENOON

AFTERNOON

DAY-1 Process designing, Equipment and System Design criteria

Pressure Vessel design

DAY-2 Heat Exchanger Design, Rotating

equipment designSteam Generator Design

DAY-3 Steam turbine design consideration Piping layout& Piping Design, Design of

Ash handling systems and equipment DAY-4 Electrical System Design Design of HT/LT motors DAY-5 Design of transformers Instrumentation System Design

46


Module : Load Dispatch (Duration) : 1 Week

FORENOON AFTERNOONDAY - 1 Objective, functions and structure of

Load dispatching stations – An overview.

Location of load dispatch stations – area, state and regional and their functions – Voltage and frequency control. Trends in design and engineering of load dispatch / systems.

DAY - 2 MW and AVAR sharing between stations and systems voltage control- Concept of base load and peak load operations - Economic dispatch aspects.

Load forecasting - Short tern and long term.

DAY - 3 Application of computers - DAS, RTUs and SCADA.

HVDC systems and SVC operation.

DAY - 4 Networking and protocol for data exchange latest developments.

PC based power system study package.

DAY – 5 Visit to load dispatch centre. Group discussion and appraisal.

47


Module : Power Reforms and Regulations (Duration): 1 week

1st WEEK

FORENOON

AFTERNOON

DAY-1 Power sector reforms-the Indian perspective, Indian Electricity Act 2003

National electricity policy, energy conservation act

DAY-2 Power sector reforms in

Generation, TransmissionDistribution Reforms

DAY-3 CERC-Functions and

responsibilities Case studies on Open Access system- long term and short term

DAY-4 National Tariff policy/ Multi year

tariff/ABTAPDRP/RGGVY Scheme

DAY-5 Power Trading and Sharing Case studies on tariff discovery through

competitive bidding, quality of power

48


Module : Control & Instrumentation(Duration) : 2 Weeks

1st WEEK

FORENOON AFTERNOONDAY - 1 Concept and .layout of Control and

Instrumentation in Thermal Power Plant.

Pressure Measurement and measuring instruments.

DAY - 2 Temperature measurement and measuring Instruments.

Flow measurement and measuring Instruments.

DAY - 3 Level Measurement and measuring Instruments.

Practical demonstration on pressure and flow measurements.

DAY - 4 Practical demonstration on level and temperature measurements.

Protection and interlocks of Boiler, turbine and their auxiliaries.

DAY – 5 Introduction to auto control. Auto control loops used in thermal stations.

49


Module : Control & Instrumentation (Duration) : 2 Weeks 2nd WEEK

FORENOON AFTERNOONDAY - 1 Turbovisory instrumentation (Parameters

limits, Basic concepts of measuring devices).

Commissioning of control loops demonstration.

DAY - 2 ATRS. Visit to control and instrument at control/control stations in the stations.

DAY - 3 Analytical Instrumentation for (Boiler Water, Steam, Flue Gas, H2/02/C02).

Practical demonstration and analytical instruments. (Correct : sampling and testing).

DAY - 4 Introduction to DOC and DAS in Thermal Power Station.

Continued ...

DAY – 5 Introduction to new/latest technology in Control and Instrumentation in modern thermal power station.

Group discussion (Performance)

50


Module : IT Application in Power Sector & GIS (Duration) : 2 Weeks

1st week

FORENOON AFTERNOONDAY - 1 Core of Information Technology (IT)

Information Technology OverviewData Structures

Development of Computer TechnologyCommunication & NetworkingData Processing Techniques

DAY - 2 Hands-on practice on Windows, MS-Office and Typical Application Packages.

4 Exercises of ½ Hour duration to be done in this session.

Computer Networks – Resource Sharing – Network Topologies – Network Hardware – Wired vs. Wireless Networks – Wi-fi & Bluetooth Communications – Limitations - Client/Server Architecture - LAN, WAN, TCP/IP - Network Security.

DAY - 3 Hands-on practice on troubleshooting and general maintenance of Computers and Peripherals. Disk Cleanup – Defragmentation – Detecting and Clearing Software Virus & Spyware – Preventive Maintenance Procedures

Network and Internet based Communications – Domains – DNS, SLIP, PPP, FDDI - Browsers, Servers, Search Engines – Email - File Transfer Protocol (FTP) - Telnet - Internet Relay Chat - Instant Messaging – Cyber Laws

DAY - 4 Hands-on practice on Windows 2000 or higher network O/S – Configuring Workgroups – Configuring – TCP/IP - File/Folder Sharing, Printer Sharing and Internet Sharing.

Internet Management - Security Concepts, Information Privacy and Copyright issues – Web Hosting - Commerce on Internet - Governance on Internet – Management Information Systems.

DAY – 5 Hand-on practice on implementing a Network based Management Information System using MS-Access

Project Management Software – MS-Project / Primavera.

.

51


Module : IT Application in Power Sector & GIS (Duration) : 2 Weeks

2nd week

FORENOON AFTERNOONDAY - 1 Concept of Geographical Information

System (GIS)Basics of GeographyHardware & Software Requirement

Fundamentals of GIS and MappingData VisualisationThematic Map Preparation

DAY - 2 Concepts of Remote Sensing Technology (RS)Basics of Remote SensingElectromagnetic Energy

Elements of Remote SensingFundamentals of Photogrammetry

DAY - 3 Concepts of Global Positioning System (GPS)Basics of GPS

Concepts of Global Positioning System (GPS)Working with GPS/DGPS

DAY - 4 Applications of GIS/RS in –Power Generation

Applications of GIS/RS in –Power Transmission and Distribution

DAY – 5 Working with ARC-FM & CYMDIST software

Working on various softwares for distribution network planning and analysis

.

52


Module : Environment Management Duration : 1 week

FORENOON AFTERNOONDAY - 1 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. Environmental Protection Act (EPA)-1986

DAY - 2 Water pollution due to thermal power station (Water pollutant and their effect on eco-system, waste water treatment, zero discharge concept).

Demonstration of monitoring water quality.

DAY - 3 Air Pollution caused by coal and oil at.source and due to combustion of coal and oil, stack emission ESP etc.

Demonstration of monitoring Air quality

DAY - 4 Disease caused due to thermal power plant pollution and other impact.

Environmental impact, assessment environmental audit.

DAY – 5 Role of NGOs and media. Appraisal.

Module : ROJ (Maintenance)53


Duration:4 Weeks 1ST WEEK

FORENOON AFTERNOONDAY - 1 Boiler Maintenance (Acquaintance

with various tools and tackles, Lifting and material handling equipments, consumables and spares).

Turbine stop valves and control valve mtc., Turbine governing system setting, Gland sealing system inspection, Deaerator maintenance. Overhauling of oil system, oil coolers, testing for leakage, flushing of main oil tanks etc

DAY - 2 Boiler Drum (Drum internal and mounting inspection) Firing Floor (Oil guns, igniter, air, fans, scanner air fans, Air heater, soot blowers, wind box, burner, tilt and coal feeder).

Turbine Basement/ ‘0’ meter (condenser tube cleaning, CW Pump Maintenance)

DAY - 3 Furnace (Boiler tube leakage attending during shut down), edge preparation and welding, post heating etc. , Weld defects testing by NDT method, stress relieving, Coal Mills (Preventive maintenance and overhauling activities, Inspection of classifier blades. Inspection of bull ring segment replacement. Thrust bearing and gear box replacement).

Turbine Basement/ ‘0’ meter (BFP maintenance, inspection of bearing, inspection of balancing system, inspection of mechanical system, Hydraulic coupling scoop mechanisms, Adjustments of lube oil pressure and filter cleaning , BFP alignment). HP-LP Hearers Detection of tube leakage and plugging, Alternating water box leakage).

DAY - 4 ID, FD & PA Fans (Preventive maintenance and overhauling activities, Vibration points).ESP and Ash Handling System (ESP maintenance fly ash maintenance, clinker grinder, bottom ash, slurry pumps etc.)

HP-LP Heaters (Oil Pumps maintenance Centrifuge bowl cleaning), CT Fans(Preventive maintenance of CT Fans and Gear box, Trays and Nozzle cleaning, Fan blades angle adjustment

DAY – 5 Turbine Maintenance Stores (Acquaintance with various tools and tackles, Lifting and equipments, consumables and spares).

Water treatment plant and Hydrogen plant (Maintenance of raw water pump and DM pump. Maintenance of H2 for compressors).

Module : ROJ (Maintenance)

54


Duration: 4 Weeks 2nd WEEK

FORENOON AFTERNOONDAY - 1 Coal Handling Plant (Crusher

maintenance Conveyor maintenance. Feeder maintenance). Coal Handling Plant (Tripper maintenance, Stacker cum Reclaimer maintenance

Exposure to maintenance and testing requirements for Drives

DAY - 2 Oil Handling Plant (Oill heaters maintenance, Oil pumps rotary and reciprocating pump etc., Filters/strainers maintenance).

Exposure to maintenance and testing requirements for TSE

DAY - 3 Familiarisation of organisation procedures for routine and preventive maintenance, breakdown and emergency repairs and Instrument lab. set up for calibration and repairs.

Exposure to maintenance and testing requirements for Temperature Instrument

DAY - 4 Exposure to maintenance and testing requirements of pressure, flow and level instruments at site and in lab.

. Exposure to maintenance and testing requirements for DDC, DAS etc.

DAY – 5 Transformers Electric Generator

55


Module : ROJ (Maintenance)

Duration: 4 Weeks 3rd

WEEK

FORENOON AFTERNOONDAY - 1 Circuit Breakers ……. Continue

DAY - 2 Electric Motors ……. Continue

DAY - 3 Electro Static Precipitator ……. Continue

DAY - 4 Cables

DAY – 5 Relays and Soleenoid ……. Continue

56


Module : ROJ (Maintenance)Duration: 4 Weeks

4th WEEK

FORENOON AFTERNOONDAY - 1 Cranes Lift

DAY - 2 Air Conditioning System Diesel Set

DAY - 3 HT/LT Supply Circuits HT/LT Supply Circuits

DAY - 4 AC/DC Lighting Circuits Batteries

DAY – 5 Viva Voce Viva Voce

57


Module : Visit to Manufacturing Units/TPSDuration: 2 Weeks

1ST WEEK

DAY - 1 Monday - Travelling

DAY - 2 Tuesday – Visit to BHEL, Hardwar/ Visit to Chandrapur TPS, MSEB

DAY - 3 Wednesday – Travelling

DAY - 4 Thursday – Visit to BHEL, Hyderabdad

DAY – 5 Friday - Visit to BHEL, Bangalore

DAY - 6 Saturday - Travelling

Note:- The tour programme can be adjusted by the Institute depending their convenience.

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Module : Visit to Manufacturing Units/TPS

(Duration) : 2 Weeks2ND WEEK

DAY - 1 Monday – Visit to Neyveli/Vijaywada TPS

DAY - 2 Tuesday – Travelling

DAY - 3 Wednesday – Visit to BHEL, Trichy/ Visit to Trombay, TPS

DAY - 4 Thursday – Visit to BHEL, Bhopal / Visit to Uran Gas Based PS, MSEB

DAY – 5 Friday - Travelling

DAY - 6 Saturday – Visit to BHEL, Ranipet/ Visit to DESU Gas Turbine Project

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Module : Simulator(Duration) : 2 Weeks

1ST WEEK

FORENOON AFTERNOONDAY - 1 Introduction to Simulator Centre Description of Different Boiler

system and boiler lit up.

DAY - 2 Pre-checks and system-line up activities for Boiler lit up. Boiler lit up after getting purge complete condition.

DAY - 3 Pre-checks and system line up activities in turbine side (Starting CEP, BEPs and charging condensate/feed water system, Charging turbine oil system, starting oil pumps and putting B/G on operation, Charging Aux. steam and starting vacuum pulling in condenser).

Unit start up from cold condition.

DAY - 4 Pressure raising in Boiler (Checking various interlocks and protection, Changing over of auxilaries).

HP/LP By pass operation

DAY – 5 Charging steam lines (Operation of HP/LP By pass, Operation of turbine sidedrains/vents, M/C Rolling and Synchronisation).

Milling Plant Operation.

Module : Simulator (Duration) : 2 Weeks

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2 ND WEEK

FORENOON AFTERNOONDAY - 1 Milling Plant Operation and raising

pressure as per Boiler load requirements (Operation of second set of auxiliaries and load sharing, Change over of controls from manuals to auto).

Discussion on: (Milling Plant, Burner, Optimum Sec. Air and Drum Level control, Burner Mechanism and attemperators).

DAY - 2 Raising load in TG (Operation of second set of auxiliaries and load sharing, Checking of protections, Changeover of controls –from manual to auto).

Unit shutting down procedures.

DAY - 3 Shutting down unit from full load to 30 MW and again raising load to full load condition.

Unit start up from hot and warm conditions.

DAY - 4 Tripping unit from full load on some protection and start up again from hot condition.,

Emergency problems in unit (Boiler. Turbine and Generator).

DAY – 5 Operation unit under emergency situation.

Summing up programme/Appraisal.

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