ntpc trainingreport(5)

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Training Report On Application of Control and instrumentation & IT in plant management Submitted in the partial fulfillment of the requirement for the award of degree of Bachelors of Technology In Electronics & Communication Engineering Submitted by: Name: Arpit Agarwal Reg. Number:10902517 Name and Location of Company: NTPC Limited 1

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Page 1: NTPC TRAININGREPORT(5)

Training Report

On

Application of Control and instrumentation&

IT in plant management

Submitted in the partial fulfillment of the requirement for the award of degree

of

Bachelors of Technology

In

Electronics & Communication Engineering

Submitted by:

Name: Arpit AgarwalReg. Number:10902517

Name and Location of Company:NTPC Limited

Badarpur Thermal Power Station(BTPS)Period Training: 04/06/2012- 13/07/2012

Department of Electronics & Comm. EnggLovely Professional University

Phagwara–140 401, Punjab (India)

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Ph. (01824-506960-61) Department of Electronics & Communication Engineering

Lovely Professional University Phagwara (Distt. Kapurthala) Punjab India 144001

Ref:__________ Dated: __________

Certificate

This is to be Certified that this Training entitled “Control system and instrumentation and IT submitted

by Arpit Agarwal(RE6911B32), student of Electronics & Communication Engineering Department,

Lovely Professional University, Phagwara Punjab in the partial fulfillment of the requirement for the

award of Bachelors of Technology (Electronics & Communication Engineering) Degree of LPU, is a

record of student’s own study carried under my supervision & guidance.

Name and Signature of Training Supervisor

Designation

Head of the Domain

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Acknowledgement

Engineering is the art of organizing and directing men and controlling the forces and materials of

nature for the benefit of the human race. But a true Engineering is the engineering with a practical

knowledge. I owe a heartiest gratitude to NTPC Limited BTPS for providing me an internship in its

prestigious organization. I wish to express my deep sense of gratitude to Ms. Rachna Singh Bhal (Sr.

Manager, EDC) for providing me an opportunity to undergo my training at NTPC Badarpur. I am also

thankful to my training Mentor Ms.Sonia singh (C&I) and Mr. for their efforts in making of this

project. My regard and gratitude to Mr. Vijay Goel(Director of NTPC) seeks no bounds due to his

efforts in supervising me and my project.

Finally, yet importantly, I would like to express my heartfelt thanks to my beloved parents for their

blessings, my friends for their help and wishes for the successful completion of this project.

ARPIT AGARWAL (Trainee, NTPC)

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TABLE OF CONTENTS

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S.NO. TITLE PAGE NO.

1. ABOUT THE ORGANISATION 9 1.1 INTRODUCTION 9-11

2. FLOW CHART OF THE PROCESS AT THE 12 ORGANISATION

2.1 COAL PROCESS 12

2.2 CONDENSATION PROCESS 13

2.3 FEED WATER PROCESS 14

2.4 STEAM PROCESS 15

3. EXPLANATION OF PROCESS AT THE 16 ORGANISATION

3.1 COAL TO ELECTRICITY 16-19

3.2 BOILER MAINTENANCE DEPARTMENT 20-21

3.2.1 BOILER FURNACE AND STEAM DRUM 21

3.2.2 FUEL PREPARATION SYSTEM 21-22

3.2.3 FUEL FIRING SYSTEM AND IGNITE SYSTEM 22

3.2.4 AIR PATH 22-23

3.3 OPERATION AND WORKING OF TURBINE 23-24

3.4 BOILER DRUM 24-26

3.5 ELECTROSTATIC PRECIPITATOR 26 3.6 PRIMARY AIR FAN 26-27

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3.7 ASH HANDLING PLANT 27

3.8 COAL HANDLING PLANT(C.H.P) 28

3.9 MAJOR COMPONENTS 28-301) WAGON TIPPLER

2) CONVEYER

3) CRUSHER

4) RC FEEDER

5) BOWL MILL

6) MILL FANS

4. DETAILS OF WORK/JOB ASSIGNED 30

4.1 CONTROL AND INSTRUMENTATION(C&I) 30-31

4.1.1 OPERATION AND MAINTENANCE 31-32

4.1.2 MANOMETRY LAB 32-35

a. Pressure

b. Level

c. Flow 33-35

a) ORIFICE PLATES

b) ROTAMETERS

c) VENTURI TUBES

4.1.3 MANOMETERS 36-37

Types of manometers

1. U tube manometers

2. Capsule type manometers

3. C-type bourdon pressure gauge

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4. Compound gauge

5. spiral gauge

6. Helical type gauge

7. Diaphragm type

4.1.4 DIFFERENTIAL PRESSURE TRANSMITTER 37

4.1.4.1 FC SERIES DIFFERENTIAL PRESSURE 37-38

TRANSMITTER

4.1.5 PROTECTION AND INTERLOCKING LAB 38-39

o Interlocking

o Relay

o Fuses

o Miniature circuit breakers

4.1.6 PROTECTION AND INTERLOCKING SYSTEM 39

o HIGH TENSION CONTROL CIRCUIT

o LOW TENSION CONTROL CIRCUIT

4.1.7 AUTOMATION LABS 40

4.1.8 PYROMETRY LAB 40-41

o Thermocouples

o RTDs

o Liquid in glass Thermometers

4.1.9 ELECTRONICS LAB 41-42

4.2 BTPS IT VISION 43

4.2.1 IT ROLE & RESPONSIBILITIES @ BTPS 43

4.2.2 IT APPLICATION@BTPS 43

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4.2.3 Benefits of IT Innovations @ BTPS 43

4.2.3.1 OPERATION 43-44

4.2.3.2 MAINTENACE 44

4.2.3.3 MATERIALS 44

4.2.3.4 OFFICE AUTOMATION AND COMMUNICATION 44

4.2.4 BTPS IT APPLICATIONS HIGHLIGHTS 44-45

4.2.5 ERP/SAP MODULES IMPLEMENTED (ERP-ENTERPRISE RESOURCES PLANNING) 46

4.2.6 MAINTENANCE MANAGEMENTSYSTEM,ANURAKSHAN

@ BTPS 46

4.2.7 MATERIAL AND CONTRACT MANAGEMENT SYSTEM(CMS) 46

4.2.8 FINANCIAL ACCOUNTING SYSTEM(FAS) 46

4.2.9 COAL ACCOUNTING SYSTEM (CAS) 46

4.2.10 HOSPITAL MANAGEMENT SYSTEM (HMS) 47

4.2.11 HR/TRAINING MANAGEMENT SYSTEM 48

4.2.12 SMS ALERT @ BTPS 49

4.2.13 RECORDS AND RECOGNITIONS 49

5. LEARNING OUTCOMES AND ANALYSIS 50-53

6. CONCLUSIONS 54

7. FUTURE SCOPE OF THIS TYPE TRAINING 55

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1. ABOUT THE ORGANIZATION

1.1 INTRODUCTION

ABOUT NTPC

NTPC Limited is the largest thermal power generating company of India.

A public sector company, it was incorporated in the year 1975 to accelerate power development in the country as a wholly owned company of the Government of India.

JOURNEY OF NTPC 1975 -NTPC was set up in 1975 with 100% ownership by the Government of India. In the last

30 years, NTPC has grown into the largest power utility in India.

1997 -In 1997, Government of India granted NTPC status of “Navratna’ being one of the nine jewels of India, enhancing the powers to the Board of Directors.

2004 -NTPC became a listed company with majority Government ownership of 89.5%. NTPC \

becomes third largest by Market Capitalization of listed companies.

2005 - The company rechristened as NTPC Limited in line with its changing business portfolio and transforms itself from a thermal power utility to an integrated power utility.

2008 -National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it 411th in the world.

2009 -National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it 317th in the world.

2012 -NTPC has also set up a plan to achieve a target of 50,000 MW generation capacity.

2017-NTPC has embarked on plans to become a 75,000 MW company by 2017.

NTPC has installed capacity of around 38,600 MW (20%) out of our world’s installed capacity which is around ~2,00,000 MW.

Generation through these plants NTPC provide 25% or 1/4th of total country electricity.

The distribution of sectors along with company names that provide electricity:

PSU’S- NTPC,NHPC etc.

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PRIVATE –Tata, Reliance, J.P. etc.

Distribution of Generation of electricity: Out of 100% electricity generated 65%is distributed in such a way:

I. 55% through coal & 10% through gas.

II. 20% is generated through hydel source &

III. 12% through renewable energy sources for ex-wind, solar energy etc.

IV. 3%is generated through nuclear energy resources.

Thermal is the biggest energy source.

Now only coal has been left to generate the electricity but coal is not able to fulfill the power requirements of NTPC so NTPC diverse its path and it goes to energy field so that’s why the name of NTPC has now been changed to NTPC ltd.

NTPC has set new benchmarks for the power industry both in the area of power plant construction and operations.

VISION AND MISSION OF NTPC

VISION:- “A world class integrated power major, powering India's growth with increasing global presence.”

MISSION:-“Develop and provide reliable power, related products and services at competitive prices, integrating multiple energy sources with innovative and eco-friendly technologies and contribute to society.

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STARETEGIES: Sustainable Development Nuturing Sector Human Leadership Resource STRATEGIES

Technology Further Initiatives Enhance Fuel Security Exploit New Business Opportunities

Performance

In terms of operations, NTPC has always been considerably above the national average. The availability factor for coal based power stations has increased from 89.32% in 1998-99 to 92.47% in 2008-09, which compares favorably with international standards. The PLF has increased from 76.6% in 1998-99 to 91.14% during the year 2008-09.

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2. FLOW CHART OF THE PROCESS AT THE ORGANISATION

2.1 COAL PROCESS:

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2.2 CONDENSATION PROCESS:

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2.3 FEED WATER PROCESS:

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2.4 STEAM PROCESS:

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3. EXPLANATION OF PROCESS AT THE ORGANISATION

3.1 COAL TO ELECTRICITY:

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Fig.1 NTPC BADARPUR THERMAL POWER PLANT

Coal from the coal wagons(Coal stock yard) is unloaded in the coal handling plant. This Coal is transported up to the raw coal bunkers with the help of belt conveyors.

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Fig.2. RAILWAY TRACK FOR THE RAIL HAVING COALWAGONS TO REACH THE COAL YARD

Fig.3 VIEW OF COAL YARD FROM A FEW DISTANCE

Fig.4 BELT CONVEYERS

Coal is transported to Bowl mills and vowl mills by Coal Feeders i.e. RC feeder as shown in figure.5.

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Fig.5 RC FEEDER

The coal is pulverized in the Bowl Mill, where it is ground to powder form. The mill consists of a round metallic table on which coal particles fall as shown below in fig.6.

Fig.6 PULVERIZER

This table is rotated with the help of a motor. There are three large steel rollers, which are spaced 120 apart.

When there is no coal, these rollers do not rotate but when the coal is fed to the table it packs up between roller and the table and thus forces the rollers to rotate.

This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from P.A. Fan.

P.A. Fan takes atmospheric air, a part of which is sent to Air-Preheaters for heating while a

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part goes directly to the mill for temperature control. Atmospheric air from F.D. Fan is heated in the air heaters and sent to the furnace as

combustion air.

Water from the boiler feed pump passes through economizer and reaches the boiler drum.

Water from the drum passes through down comers and goes to the bottom ring header.

Water from the bottom ring header is divided to all the four sides of the furnace.

Due to heat and density difference, the water rises up in the water wall tubes.

Water is partly converted to steam as it rises up in the furnace. This steam and water mixture is again

Taken to the boiler drum where the steam is separated from water.

Water follows the same path while the steam is sent to super heaters for superheating. The super

heatersare located inside the furnace and the steam is superheated (540C) and finally it goes to the turbine.

Flue gases from the furnace are extracted by induced draft fan, which maintains balance draft in the

furnace (-5 to –10 mm of wcl) with forced draft fan.

These flue gases emit their heat energy to various super heaters in the pent house and finally pass

through air-preheaters and goes to electrostatic precipitators where the ash particles are extracted.

Electrostatic Precipitator consists of metal plates, which are electrically charged.

Ash particles are attracted on to these plates, so that they do not pass through the chimney to pollute

the

atmosphere. Regular mechanical hammer blows cause the accumulation of ash to fall to the bottom of the precipitator where they are collected in a hopper for disposal.

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3.2 BOILER MAINTENANCE DEPARTMENT:

The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter as shown in figure.7.

Fig.7. BOILER

Fig.8. Boiler Side of the Badarpur Thermal Power Station, New Delhi

Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the center.

The thermal radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter.

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The water circulation rate in the boiler is three to four times the throughput and is typically driven by pumps.

As the water in the boiler circulates it absorbs heat and changes into steam at 700 °F and 22.1 MPa.

It is separated from the water inside a drum at the top of the furnace.

The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace.

Here the steam is superheated to 1,000 °F (540 °C) to prepare it for the turbine.

The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator.

The generator includes the economizer, the steam drum, the chemical dosing equipment, and the furnace with its steam generating tubes and the super heater coils.

Necessary safety valves are located at suitable points to avoid excessive boiler pressure.

The air and flue gas path equipment include: forced draft (FD) fan, air pre heater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or bag house) and the flue gas stack.

3.2.1 BOILER FURNACE AND STEAM DRUM:

Once water inside the boiler or steam generator, the process of adding the latent heat of vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical reaction of burning some type of fuel.

The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to the steam drum.

Once the water enters the steam drum it goes down the down comers to the lower inlet water wall headers.

From the inlet headers the water rises through the water walls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear water walls (typically).

As the water is turned into steam/vapour in the water walls, the steam/vapor once again enters the steam drum.

3.2.2 FUEL PREPARATION SYSTEM:

In coal-fired power stations, the raw feed coal from the coal storage area is first crushed into small pieces and then conveyed to the coal feed hoppers at the boilers.

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The coal is next pulverized into a very fine powder. The pulverizes may be bowl mills, rotating drum grinders, or other types of grinders.

Some power stations burn fuel oil rather than coal. The oil must kept warm (above its pour point) in the fuel oil storage tanks to prevent the oil from congealing and becoming un-pump able.

The oil is usually heated to about 100°C before being pumped through the furnace fuel oil spray nozzles.

3.2.3 FUEL FIRING SYSTEM AND IGNITE SYSTEM:

From the pulverized coal bin, coal is blown by hot air through the furnace coal burners at an angle which imparts a swirling motion to the powdered coal to enhance mixing of the coal powder with the incoming preheated combustion air and thus to enhance the combustion.

To provide sufficient combustion temperature in the furnace before igniting the powdered coal,

the furnace temperature is raised by first burning some light fuel oil or processed natural gas (by using auxiliary burners and igniters provide for that purpose).

3.2.4 AIR PATH:

External fans are provided to give sufficient air for combustion. The forced draft fan takes air from the atmosphere and, first warming it in the air preheater for better combustion, injects it via the air nozzles on the furnace wall as shown in figure.9.

Fig.9.AIR PREHEATER

The induced draft fan assists the FD fan by drawing out combustible gases from the furnace, maintaining a slightly negative pressure in the furnace to avoid backfiring through any opening.

At the furnace outlet, and before the furnace gases are handled by the ID fan, fine dust carried by the outlet gases is removed to avoid atmospheric pollution.

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Fig.10. ID FAN

This is an environmental limitation prescribed by law, and additionally minimizes erosion of the ID fan as shown in figure.10.

3.3 OPERATION AND WORKING OF TURBINE:

Fig.11.TURBINE

Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators, which produce electricity. The turbines themselves are driven by steam generated in 'Boilers' or 'Steam Generators' as they are sometimes called as shown in fig.11.

Energy in the steam after it leaves the boiler is converted into rotational energy as it passes through the turbine. The turbine normally consists of several stages with each stage consisting of a stationary blade (or nozzle) and a rotating blade.

Stationary blades convert the potential energy of the steam (temperature and pressure) into kinetic energy (velocity) and direct the flow onto the rotating blades.

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The rotating blades convert

the kinetic energy into forces, caused by pressure drop, which results in the rotation of the turbine

shaft. The turbine shaft is connected to a generator, which produces the electrical energy.

The rotational speed is 3000 rpm for Indian System (50 Hz) systems and 3600 for American (60

Hz) systems.

In a typical larger power stations, the steam turbines are split into three separate stages, the first being the High Pressure (HP), the second the Intermediate Pressure (IP) and the third the Low Pressure (LP) stage, where high, intermediate and low describe the pressure of the steam.

After the steam has passed through the HP stage, it is returned to the boiler to be re-heated to its original temperature although the pressure remains greatly reduced.

The reheated steam then passes through the IP stage and finally to the LP stage of the turbine.

High-pressure oil is injected into the bearings to provide lubrication.

3.4 BOILER DRUM:

Drum is of fusion-welded design with welded hemispherical dished ends.

It is provided with stubs for welding all the connecting tubes, i.e. down comers, risers, pipes, saturated steam outlet.

The function of steam drum internals is to separate the water from the steam generated in the furnace walls and to reduce the dissolved solid contents of the steam below the prescribed limit of 1 ppm and also take care of the sudden change of steam demand for boiler.

The secondary stage of two opposite banks of closely spaced thin corrugated sheets, which direct the steam and force the remaining entertained water against the corrugated plates.

Since the velocity is relatively low this water does not get picked up again but runs down the plates and off the second stage of the two steam outlets.

From the secondary separators the steam flows upwards to the series Of screen dryers, extending in layers across the length of the drum. These screens perform the final stage of the separation.

Once water inside the boiler or steam generator, the process of adding the latent heat of vaporization or enthalpy is underway.

The boiler transfers energy to the water by the chemical reaction of burning some type of fuel.

The water enters the boiler through a section in the convection pass called the economizer.

From the economizer it passes to the steam drum. Once the water enters the steam drum it goes down the down comers to the lower inlet water wall headers.

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Fig.12. THE ECONOMIZER

The function of an economizer in a steam-generating unit is to absorb heat from the flue gases

and add as a sensible heat to the feed water before the water enters the evaporation circuit of

the boiler as in figure .12.

From the inlet headers the water rises through the water walls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear water walls (typically).

As the water is turned into steam/vapour in the water walls, the steam/vapour once again enters the steam drum.

The steam/vapour is passed through a series of steam and water separators and then dryers inside the steam drum.

The steam separators and dryers remove the water droplets from the steam and the cycle through the water walls is repeated. This process is known as natural circulation.

The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers, water lancing and observation ports (in the furnace walls) for observation of the furnace interior.

Furnace explosions due to any accumulation of combustible gases after a tripout are avoided by flushing out such gases from the combustion zone before igniting the coal.

The steam drum (as well as the superheater coils and headers) have air vents and drains needed for initial start-up.

The steam drum has an internal device that removes moisture from the wet steam entering the drum

from the steam generating tubes. The dry steam then flows into the superheater coils.

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Geothermal plants need no boiler since they use naturally occurring steam sources.

Heat exchangers may be used where the geothermal steam is very corrosive or contains excessive suspended solids.

Nuclear plants also boil water to raise steam, either directly passing the working steam through

the reactor or else using an intermediate heat exchanger.

3.5 ELECTROSTATIC PRECIPITATOR:

This dust collector employs an electrostatic field between two sets of electrodes other and between which the flue gases are made to pass.

The dust particles are joined as the gases passes through the electric field, and are attracted by the collecting electrode which is grounded.

Then the roller hammers, which are operated with the help of motors, strike the electrode simultaneously to bring the ash down to the hoppers.

Ash collected in hoppers is then mixed with water and mixed with the slurry coming through scrapper conveyor.

The efficiency of ESP is 90% in dust collection.

3.6 PRIMARY AIR FAN:

PA Fan if flange-mounted design, single stage suction, NDFV type, backward curved bladed radial fan operating on the principle of energy transformation due to centrifugal forces as shown in figure.13.

Fig.13.PRIMARY AIR FAN

Some amount of the velocity energy is converted to pressure energy in the spiral casing.

The fan is driven at a constant speed and varying the angle of the inlet vane control controls the

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flow.

The special feature of the fan is that is provided with inlet guide vane control with a positive

and precise link mechanism.

3.7 ASH HANDLING PLANT:

Fig.14Ash Handling System at Badarpur Thermal Power Station

At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from

the bottom of the furnace as in figure.14.

This hopper is always filled with water to quench the ash and clinkers falling down from the

furnace.

Some arrangement is included to crush the clinkers and for conveying the crushed clinkers and

bottom ash to a storage site.

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3.8 COAL HANDLING PLANT:

The old coal handling plant caters to the need of units 2,3,4,5 and 1 whereas the latter supplies

coal to units 4 and V.O.C.H.P. supplies coal to second and third stages in the advent coal to

usable form to (crushed) form its raw form and send it to bunkers, from where it is send to

furnace as in figure.15.

Fig.15.COAL HANDLING PLANT(C.H.P.)

3.9 MAJOR COMPONENTS:

1) WAGON TIPPLER

o Wagons from the coal yard come to the tippler and are emptied here.

o Tippler has raised lower system which enables is to switch off motor when required till is

wagon back to its original position. It is titled by weight balancing principle.

o The motor lowers the hanging balancing weights, which in turn tilts the conveyor.

o Estimate of the weight of the conveyor is made through hydraulic weighing machine.

2) CONVEYER

o Conveyors have a capacity of carrying coal at the rate of 400 tons per hour. Few

conveyors are double belt, this is done for imp.

o Conveyors so that if a belt develops any problem the process is not stalled.

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o The conveyor belt has a switch after every 25-30 m on both sides so stop the belt in case of

emergency.

o The conveyors are made of chemically treated vulcanized rubber.

o The max angular elevation of conveyor is designed such as never to exceed half of the

angle of response and comes out to be around 20 degrees.

3) CRUSHER

o Both the plants use TATA crushers powered by BHEL,MOTORS.

o The crusher is of ring type.

o Crusher is practically considered as the optimum size of transfer via conveyor.

4) RC FEEDER

o It transports pre crust coal from raw coal bunker to mill.

o The quantity of raw coal fed in mill can be controlled by speed control of aviator drive

controlling damper and aviator change.

5) BOWL MILL

o The bowl mill crushes the raw coal to a certain height and then allows it to fall down.

o Due to impact of bowl on coal and attraction as per the particles move over each other as

well as over the Armor lines, the coal gets crushed.

o Large particles are broken by impact and full grinding is done by attraction.

o The Drying and grinding option takes place simultaneously inside the mill.

6) MILLS FANS

o It is of 3 types:

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(a) ID Fans: - Located between electrostatic precipitator and chimney.

Type-radical

Lubrication-by oil

(b) FD Fans: - Designed to handle secondary air for boiler. 2 in number and provide ignition

of coal.

Type-axial

(c)Primary Air Fans: - Designed for handling the atmospheric air up to 50 degrees Celsius, 2

in number And they transfer the powered coal to burners to firing.

Type-Double suction radial

Lubrication-by oil

Type of operation-continuous

4. DETAILS OF WORK/JOB ASSIGNED

4.1 CONTROL AND INSTRUMENTATION(C&I):

Control and instrumentation deals with the various measurement, indication, transmission and

control in different technical fields.

Instrumentation is for measurement of various parameters.

And controlling various parameters from a remote control room as in figure.16.

Basically in the plant the hardware is used only in boiler so the instruments present in the labs

are used at the boiler site mainly.

Instruments are used for measuring various physical quantities like

a. Pressure

b. Temperature

c. Level

d. Flow

e. Turbovisory

Vibration

Speed etc.

f. Analytical

Ph

Conductivity

Silica etc.

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Measuring electrical parameters such as

a. Load

b. Mvar

c. Frequency

d. Voltage current etc.

Indicators

a. Local

b. Remote

Recorders

a. Single point

b. Multipoint

c. Continuous

d. Dotted

4.1.1 OPERATION AND MAINTENANCE

Control and Instrumentation Department has following Control Units:

1. Unit Control Board

2. Main Control Board

This department is the brain of the plant because from the relays to transmitters followed by the electronic computation chipsets and recorders and lastly the controlling circuitry, all fall under this.

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Fig.16. A VIEW OF CONTROL ROOM AT BTPS Control and instrumentation department is divided among the following labs:

4.1.2 MANOMETRY LAB

This components with which this lab deals with are used for the measurement of

a. Pressure

b. Level

c. Flow

a. Pressure

Pressure measurement is one of the most common measurement taken and recorded in

the power station ranging from very low,i.e. condenser vaccum to very high i.e. hydraulic

pressure in some actuator system. between these two limits are to be the measurement of

different process media steam water,oil,air,gas etc.

For the low pressure measurement water filled and mercury filled manometers are used.

Bellows for medium pressure.

Bourdon tube gauges for medium and high pressure measurements.

Transducers of capacitive type, lvdt type and strain gauge type are used for all ranges for

measurement purpose

b. Level

The level flow can be measured through floats and liquid displacers.\

The level flow can also be measured through head pressure measurement,DP

type,ultrasonic,direct viewing and strain gauge.

In closed pressurized vessels, differential pressure measurement is used to measure the

level.

One side condensate pot is used where constant level is maintained.

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Other side is connected to the bottom of the vessel.

Difference between these two heads gives the vessel.

c. Flow

Controlling the flow rate of liquids is a key control mechanisms for any process plant.

There are many different types of devices available to measure flow.

For the measurement of flow type head types are used that consists of:

a) Orifice plate.

b) Rota meters.

c) Venture tubes.

d) Target meters.

Head type devices measure flow by constricting stream and measuring the resulting

pressure drop.

The pressure drop can then be related to a flow.

For the measurement of flow the velocity type instruments are used that consists of:

Magnetic

Vertex

Also the displacement types are used:

Turbine meter

a) ORIFICE PLATES

An orifice plate is a very simple device installed in a straight run of pipe.

The orifice plate contains a hole smaller than the pipe diameter as can be seen in figure

17.

The flow constricts, experiences a pressure drop, and the differential pressure can be

related to a flow.

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Fig.17.ORIFICE PLATES

b) ROTA METERS

Rather than using a constant restriction area and a variable pressure

differential,rotameters use a variable restriction and a constant pressure differential to

measure flow.

Typically,rotameters are used to measure smaller flows and the reading is usually done

locally, although transmission of the readings is possible.

The rot meter consists of a float that moves vertically through a slightly tapered tube.

As fluid enters the bottom of the rotameter,the float is forced upward until the force is

balanced by gravitational forces.

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Most rot meters are made of glass with markings on the outside so that flow readings can

be taken visually.

The advantage to rot meters is the simplicity of the device and a constant pressure drop.

Also, rot meters do not require straight pipe runs for installation so they cab be installed

just about anywhere as shown in figure.18.

Fig.18.ROTAMETERS

c) VENTURI TUBES

A venture tube also measures flow rates by constricting fluids measuring a differential

pressure drop as in fig.19.

Venture tubes allow for flow measurement with lower head loss than orifice plates.

Fig.19.VENTURE TUBES

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4.1.3 MANOMETERS

Types of manometers

1. U tube manometers

The U tube manometers are widely used in laboratories usually for low pressure measurements.

The length of the column of water or mercury gives the reading in the tube in case of water it is

mm wel and in case of mercury. it is mm hg.

2. Capsule type manometers

In this type of manometer different diaphragms are connected to each other. pressure is applied

at one end, where the sensor is connected. Due to the pressure the diaphragm expand and give

momentum at the other end. the other end, as shown in the schematic diagram, is connected by a

rack and pinion arrangement. Thus we get the reading on a scale as can be seen in figure.20.

Fig.20.CAPSULE TYPE MANOMETERS

3. C-type bourdon pressure gauge

This type of pressure gauge makes use of the bourdon tube. The sensor is present at the bottom of the tube. the tube expands due to pressure, which is turn moves the rack and pinion arrangement, and thus we get the reading on the scale by the indicator. The spring is used for bringing back the indicator to its zero position once the pressure is removed.

4. Compound gauge

This type is similar to the bourdon tube gauge, the only difference being in the marking on the scale. this gauge gives readings, both, for pressure as well as vaccum.

5. Spiral gauge

A gauge similar to the C type Bourdon tube pressure gauge, with the bourdon tube replaced with a spiral. the spiral gauge is more accurate than the bourdon tube gauge, because in this we obtain more

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expansion for small values of pressure. This gauge is used for high pressure measurement.

6. Helical type gauge

In this the bourdon tube is replaced by a helix.

7. Diaphragm type

This type of gauges are used basically for the measurement of acid and oil pressure. The

diaphragm is used in these instruments because the image the material gauge if contained

directly is used.

4.1.4 DIFFERENTIAL PRESSURE TRANSMITTER

Its principle is that it is used for the accurate measurement of differential pressure such as liquid

flow, level etc. the quality of the measurement is a function of proper installation.

o Construction

Mode of connection of transmitter is that it is connected through two wire and four wire.

It consists of sensor element, two metal pieces separated by the sensor as a diaphgram. It has two

states high and one low. An insulator covers the oil filled in the system. The pressure is applied

on either side which passes through the middle and hence acts as a capacitor due to two plates

separated by an insulator.

On application of pressure the capacitance c2 increases and c1 decreases leading to formation of

differential pressure. The pressure transmitter has a variable capacitance sensing element that

converts electronically to a two wire 4-20ma dc signal.

4.1.4.1 FC SERIES DIFFERENTIAL PRESSURE TRANSMITTERS

o Introduction

FC series capacitance type electronic differential pressure transmitters provides an accurate

measurement of differential pressure. Direct sensing mechanism of the detector and lightweight

design make this transmission high by accurate and stable as seen in fig.21.

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o Specification:

o Operational principle

Fig.21 BLOCK DIAGRAM OF TRANSMITTER

The figure shows a block diagram of the FC series differential pressure transmitter. The input

differential pressure is converted into electrostatic capacitance in the detecting unit. The

variation of electrostatic capacitance is then amplified and computed in the electronic circuit to

transmit output current.

4.1.5 PROTECTION AND INTERLOCKIG LAB

o Interlocking

It is basically interconnecting two or more equipments so that if one equipment fails other one can

perform the tasks. This type of interdependence is also created so that equipments connected

together are started and shut down in the specific sequence to avoid damage. For protection of

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equipments tripping are provided for all the equipments. Tripping can be considered as the series of

instructions connected through OR GATE, which trips the circuit.

The main equipments of this lab are relay and circuit breakers. Some of the instrument uses for

protection are:.

o Relay:

It is a protective device. It can detect wrong condition in electrical circuits by constantly

measuring the electrical quantities flowing under normal and faulty conditions. Some of

the electrical quantities are voltage, current, phase angle and velocity.

o Fuses:

FUSES It is a short piece of metal inserted in the circuit, which melts when heavy current

flows through it and thus breaks the circuit.

o Miniature Circuit Breaker:

They are used with combination of the control circuits to.

Enable the staring of plant and distributors.

Protect the circuit in case of a fault. In consists of current carrying contacts, one movable and other fixed. When a fault occurs the contacts separate and are is stuck between them.

There are three types of trips I. MANUAL TRIP

II. THERMAL TRIP

III. SHORT CIRCUIT TRIP.

4.1.6 PROTECTION AND INTERLOCK SYSTEM

o HIGH TENSION CONTROL CIRCUIT

For high tension system the control system are excited by separate D.C supply. For starting

the circuit conditions should be in series with the starting coil of the equipment to energize it.

Because if even a single condition is not true then system will not start.

o LOW TENSION CONTROL CIRCUIT

For low tension system the control circuits are directly excited from the 0.415 KV A.C

supply.The same circuit achieves both excitation and tripping. Hence the tripping coil is

provided for emergency tripping if the interconnection fails.

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4.1.7 AUTOMATION LABS

This lab deals in automating the existing equipment and feeding routes. Earlier, the old

technology dealt with only (DAS) Data Acquisition System and came to be known as primary

systems. The modern technology or the secondary systems are coupled with (MIS) Management

Information System. But this lab universally applies the pressure measuring instruments as the

controlling force. However, the relays are also provided but they are used only for protection and

interlocks.

4.1.8 PYROMETRY LABS

Pyrometry lab consists of different temperature measuring instruments as we know that accurate

measurement of temperature is very important for ant industry. pyrometer lab consists of different

instruments and sensors for the measurement of temperature that are as follows:

o Thermocouples

Thermocouple is one of the simplest an most commonly used method of measuring the process

temperature. the operation of thermocouple is based upon see back effect. Thermocouple is made

up of two dissimilar wires joined together forming reference and hot junction to which the heat is

applied. a see back voltage is developed across the reference or cold junction. this voltage

changes in accordance with temperature. in this way the signal obtained from the cold junction

can be used as a measure of the temperature as can be seen in figure.22.

Fig.22.THERMOCOUPLES

o Resistance temperature detector(RTD)

It performs the function of thermocouple basically but the difference is of a resistance. In this due

to the change in the resistance the temperature difference is measured. In this lab, also the

measuring devices can be calibrated in the oil bath or just boiling water (for low range devices)

and in small furnace (for high range devices) as in figure.23.

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Fig.23 RTD

o Liquid in glass thermometer

Mercury in the glass thermometer boils at 340° C which limits the range of temperature that can be measured. It is L shaped thermometer(in fig.24) which is designed to reach all inaccessible places.

Fig.24 L SHAPED THERMOMETER

4.1.9 ELECTRONICS LAB

The FCx – a series transmitter which is available as an analog or smart type, detects the differential pressure or pressure of various fluids converts it into a current signal of 4-20ma dc and transmit it.

The operating principle of fcx-a series transmitter is shown in block diagram. The input pressure is charged into on electrostatic capacitance in the conditioning and amplification in the transmission unit, and is then output as a current of 4 to 20 ma dc.

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o Description:

Detection unit detects pressure, differential pressure or level of fluid

Transmission unit converts the detected signal into an output signal

Drain plug used for gas discharge

Zero/span adjusting screw adjusts zero

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4.2 BTPS IT VISION

INTEGRATED IT ENABLEMENT OF BUSINESS PROCESSES FOR EFFICIENTPLANT

MANAGEMENT.

INFORMATION ANYTIME ANYWHERE.

4.2.1 IT ROLE & RESPONSIBILITIES @ BTPS

Development, Implementation & Support for Local Applications

Procurement & Maintenance of IT Infrastructure ( PCs, Printers, Servers & Network LAN,WAN etc)

Support to users for ERP & modules to supplement ERP.

Customization & Implementation support for BTPS Applications to other projects.

4.2.2 IT APPLICATION @ BTPS

At BTPS, Information Technology has been used extensively to manage following

business processes-

1. Maintenance Management System 2. Materials Management System

3. Financial Accounting System

4. Contracts Management System

5. Operations & ABT Monitoring System

6. Coal Monitoring & Accounting System

7. Hospital Management System

8. HR, T/S & Training Management System 9. Office Automation & Communication System 10. E-Samadhan complaints monitoring system

4.2.3 Benefits of IT Innovations @ BTPS

4.2.3.1 OPERATIONS

Important & critical parameters of Power Plant operation are monitored online to enable effective control on operation of various equipments and reduce down time. Online load analysis &

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Generation values are monitored to have optimum load balance of various units. Auxiliary power consumption monitored and controlled. Meritorial operation practicing enabled.

4.2.3.2 MAINTENANCE

Better control over maintenance cost by way of online information available through the system. Based on failure analysis and equipment history, modified maintenance strategy of Preventive, Predictive and Risk Based maintenance is implemented. Equipment spares planning are streamlined by way of Annual requirement, Vendor wise, linked to Equipment, Standardization of defects and repair codes for easy filling of Work Order Card, for future analysis.

4.2.3.3 MATERIALS

Material Planning and Procurement system streamlined, resulting in reduction in Administrative lead Time. Further, procurement on Annual Rate Contract basis enabled through the system, Ordering on actual need basis (just in time). This further reduces lead time and Inventory carrying. Detection of duplicate and obsolete items, standardization of material description and specification, Cleaning and Weeding of redundant data, resulting in overall system improvement and functionalities, Availability of coal stock status online, reduction in demurrages paid to railways.

4.2.3.4 OFFICE AUTOMATION AND COMMUNICATION

With implementation of e-Desk/e-broadcast, e-alerts, auto mail and BTPS website, information is available instantly to all and all time, resulting in tremendous reduction in paper communication and cost.

4.2.4 BTPS IT APPLICATIONS HIGHLIGHTS

1. Single Login screen, Pass Word & Role based secured access .

2. G.U. Interface, Easy information retrieval/search facility.

3. Information captured once at source.

4. Automation of routine activities.

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Fig.25 BTPS IT APPLICATION HIGHLIGHTS

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4.2.5 ERP/SAP MODULES IMPLEMENTED (ERP-ENTERPRISE RESOURCES PLANNING)

Maintenance Management- PM Finance Management- FI Materials Management- MM Human Resource Management- HR Operations Management- OPN Employee Self Service- ESS

4.2.6 MAINTENANCE MANAGEMENT SYSTEM,ANURAKSHAN @ BTPS

1. Permit to Work Issue with detailed feedback. 2. Daily Plant Meeting minutes generated online. 3. Trends of defects priority wise /department wise for a period. 4. Equipment history with detailed feedback available. 5. Analysis of repeated equipment failure for corrective action. 6. Standardization of defects & repair codes. 7. Interface with Materials Management System & CMS for WOC cost

4.2.7 MATERIAL AND CONTRACT MANAGEMENT SYSTEM(CMS)

1. Initiation and approval of Contract Proposal.

2. Preparation of Tender Documents and approvals.

3. Preparation and processing of Bills.

4.2.8 FINANANCIAL ACCOUNTING SYSTEM (FAS) 1. Status of Income Tax Details, PF slips, Leave, Accrued Interest, and Earning Card available online.

2. Fund Flow Statements & other Reports for day to day functioning.

3. Bank Reconciliation.

4.2.9COAL ACCOUNTING SYSTEM (CAS)

1. Online uploading of Wagon wise Weight from Wagon Tipplers.

2. Coal and Rail Freight bill payments accounting & reconciliation.

3. Tariff Summary, coal accounting and MIS reports generated from the system.

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4.2.10 HOSPITAL MANAGEMENT SYSTEM (HMS)1. Online patient registration

2. Doctor’s prescription

3. Medicines issues/availability

4. Investigation reports

as can be seen in figure.26.

Fig.26. HOSPITALITY MANAGEMENT SYSTEM

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4.2.11 HR/TRAINING MANAGEMENT SYSTEM

1. Computerized Attendance recording system.

2. Employee database to record/ update information of employees

3. Township/Quarter management system.

4. Performance Management analysis & evaluation system.

Below window indicating that how the it manage the training system through e-services.(fig.27).

AUTOMATION TOWARDS COMMUNICATION

AND PAPERLESS &

COMMUNICATION OFFICE DOCUMENT

Fig.27. VARIOUS ESERVICES@ BTPS

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4.2.12 SMS ALERT @ BTPS

1. One more IT initiative for fast & convenient way to information sharing thru SMS

2. Automatic SMS alert is already in use for plant load & unit Trip. (Fig.28)

3. Send SMS instantly or scheduled date/time.

4. SMS to groups or individual numbers.

Fig.28. PLANT LOAD &UNIT TRIP SMS ALERT

4.2.13 REWARDS & RECOGNITION

Badarpur has achieved unique distinction of being; First site in NTPC, with independent initiative of Development & Implementation of new Oracle based integrated online.

Applications, with in house effort. This has been appreciated by NTPC higher management.

BTPS Received Golden Peacock award for IT Innovation in 2004.

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5. LEARNING OUTCOMES AND ANALYSIS

LEARNING OUTCOMES:

C&I systems are the nervous system of a National thermal power corporation. They monitor all aspects of the plant’s health and help respond with the care and adjustments needed.

Progress in electronics and information technology (IT) has created incentives to replace traditional analog Control and instrumentation (C&I) systems in nuclear power plants with digital I&C systems, i.e. systems based on computers and microprocessors.

Digital systems offer higher reliability, better plant performance and additional diagnostic capabilities. Analog systems will gradually become obsolete in the general IT shift to digital technology.

Most newer plants also include digital C&I systems.

Digital C&I systems have posed new challenges for the industry and regulators, who have had to build up the methods, data and experience to assure themselves that the new systems meet all reliability and performance requirements.

In general, countries with more new construction of nuclear reactors have had greater incentives and opportunities to develop the needed capabilities.

NTPC rely on C&I systems for protection, control, supervision and monitoring. The total mass of C&I related components is on the order of 1000 tones. This makes the C&I system one of the heaviest and most extensive non-building structures in any power plant.

In the control room, the I&C systems and the plant operators meet at the human-system

interface (HSI).

ANALYSIS:

MAIN FUNCTIONS OF C&I AT NTPC:

1) Sensors interfacing with the physical processes within a plant and continuously

taking measurements of plant variables such as temperature, pressure and flow etc(as in

fig.29).

2) Control, regulation and safety systems that process measurement data to manage

plant operation, optimize plant performance and keep the plant in a safe operating

envelope.

3) Human-system interfaces to provide information and allow interaction with plant

operating personnel.

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4) Surveillance and diagnostic systems that monitor sensor signals for abnormalities.

5) Actuators (e.g. valves and motors) operated by the control and safety systems to adjust

the plant’s physical processes.

Fig.29.VIEW OF CONTROL ROOM AT BTPS

6) The HSI in the control room is where plant information is translated into required operator action. It is critical to safe operation. Computerizing an HSI means incorporating features such as computerized procedures, digital displays, touch-screen interfaces, pointing devices (like mice), and large-screen overview displays. Computerization allows more tasks to be done by operators sitting at their workstations without moving about the control room.

MAIN FUNCTIONS OF IT @ BTPS:

1) Development, Implementation & Support for Local Applications

2) Procurement & Maintenance of IT Infrastructure ( PCs, Printers, Servers & Network LAN,WAN etc)

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3) Support to users for ERP & modules to supplement ERP.

4) Customization & Implementation support for BTPS Applications to other projects.

5) Maintenance Management System.

6) Financial Accounting System.

7) Coal Monitoring & Accounting System.

8) Hospital Management System.

9) E-Samadhan complaints monitoring system.

Fig.30.PLANT LOAD AND UNIT TRIP SMS ALERT

REQUIREMENTS IN ORDER TO SET UP A PLANT:

I. COAL TIE UP(COAL MINING):

As if we want to prepare coal or the electricity through coal so some company has to provide coal.

There are seven core blocks of coal provided to the NTPC.

II. WATER:

For power plant we need a lot of water so with the little amount of water also we can generate

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electricity. So, there should be water nearby and at NTPC there is a Water Treatment

Plant(WTP) in which firstly the water is demineralised so that it can be used for generation of

electricity so there is a chlorine treatment plant also which is established at NTPC because

sometimes it happens that even after demineralising the water some hazardous gases like chlorine

remain in the water which produces rust in water so after going through the chlorine treatment

plant the water becomes useful to be used in boiler.

III. LAND:

Good amount of area is required to set up a plant.

IV. CAPITAL:

NTPC entertain trainees, local people around plant. With these conditions NTPC has to compete

with the private sector also. So, with this NTPC moves forward with the aim to Gain the capital by

not causing harm to anyone but by gaining name and fame along with capital through serving for

the nation and meeting the need and demand of electricity throughout and at least some people

who really want to work but are not able to do so. So, somehow NTPC gain capital by giving

employment to poor people also.

o SOME OTHER POINTS TO BE CONSIDERED RELATED TO THE

REQUIREMENTS FOR SETTING UP A PLANT:

a. How many rupees are required to set up 1 mw.

b. At NTPC badarpur the whole plant consists of 705 mw so as 1MW is of 6 crore rupees so at

Badarpur the cost of whole set up is 705*6= 4230crore rupees.

c. Although 700mw is not a big plant in comparison to new plants but we require huge capital

to have A large amount of set up.

d. Now a days the power plant has been set up nearby fuel.

e. Electricity transmission is cheaper than coal.

f. The maximum life of a plant is 25 years.

g. The bill of coal at btps is equal to the bill of railway.

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6. CONCLUSIONS

The industrial training exposure at NTPC,Badarpur was a very new kind of experience for me.

For the first time, I saw a very big power plant. I got training in control and

instrumentation(C&I) and IT department of NTPC.

I saw various kinds of industrial instruments which were used for measuring

temperature,pressure,level and flow parameters in industries. These instruments provided a practical

approach to all the theories that we have studied in college.

Also I was shown the control labs which acted as the brain of the power plant. All activities

were monitored from here at regular basis. The errors that may occur were well taken care of.

In the IT department I come to know that how the information technology plays a big role in the plant

management and communication system at NTPC.The employees working at the It department have

developed their own application named BCOMIT using oracle based server through which they will

be able to control each and every part and every unit of the plant and also the problems faced by the

other employees of the other departments either related to medical,pc related issue, network

problems,sms alerts etc.

So, both IT and C&I departments plays their own role simultaneously without both of these

departments the power plant will not be in working state both the departments have their own

importance.

Overall, the industrial visit to NTPC was highly educational experience.

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7. FUTURE SCOPE OF THIS TYPE TRAINING

The future scope of this type training is that through this training I come to know about the practical use

and applications of C&I and I also come to know that without C&I the power plants can’t work because

without instruments such as Rtd,Thermocouples no machinery at the power plant can work. So, this

thing indicates that there is a wide scope of C&I in almost every field that is related to the power plant or

the nuclear power station which means that there are lot of opportunities for the students in this field in

the coming time so if a student or a person have sufficient knowledge of C&I also if he /she has interest

in this field along with practical implementation then he/she will get success in this field.

Also there is a huge scope of IT sector like at NTPC I got this department in my training as the second

department In which I come to know that how each and everything at the power plant is directly or

indirectly connected to IT department in such a way that if the employee working at the plant require

information about how much electricity has been generated and how much has been consumed or if

there is any problem in the plant like if any unit is going to be shut down or if there is a condition of

short circuit then immediately they can check that through the pc and can solve the problem easily.

So, both the departments have their own scope in future and at present also.

Also, The company has also set a serious goal of having 50000 MW of installed capacity by 2012 and

75000 MW by 2017. The company has taken many steps like step-up its recruitment, reviewing

feasibilities of various sites for project implementations etc. and has been quite successful till date.

NTPC will invest about Rs 20,000 crore to set up a 3,900-megawatt (MW) coal-based power project .

Company will also start coal production from its captive mine in Jharkhand in 2011–12, for which the

company will be investing about 18 billion. ALSTOM would be a part of its 660-MW supercritical

projects. ALSTOM would execute turnkey station control and instrumentation (C&I) for this project.

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