RAJASTHAN TECHNICAL UNIVERSITY , KOTA

Maharishi Arvind Institute of Engineering & Technology

Jaipur

Practical Training Report

On

“SURATGARH SUPER THERMAL POWER

STATION”

2010-2011
(12 May, 2010 - 12th June, 2010)
th

Submitted By:
ARVIND SHARMA
07EMTME021
Mechanical Engineering
2007-2011
 CONTENTS

S.NO. TOPIC REMARK

1. PREFACE

2. ACKNOWLEDGEMENT

3. ABOUT PLANT
4. PLANT FAMILIARIZATION
(i) TUBINE
(ii) BOILER
(iii) E.S.P.
(iv)COAL HANDLING PLANT
(v)ASH HANDLING PLANT
(vi) GENERATOR
(vii)
(viii)
5. CONTROL AND
INSTRUMENTATION CIRCLE
(i) SWAS PACKAGE
(ii) ATRS PACKAGE
(iii) DDC PACKAGE
(iv) FSSS PACKAGE
 PREFACE
A very important element in curriculum of an Engineering student is the
Practical Training.
I under went practical training at “SURATGARH SUPER THERMAL
POWER STATION” from 11-05-2010 to 11-06-2010. This is a part of total 30 days
training program incorporated in the curriculum of the RAJASTHAN TECHNICAL
UNIVERSITY for B.Tech. courses. This period was before my 6th sem. - B.Tech.
Exams.

As I am a student of Mechanical Branch so the training at S.T.P.S. has been

particularly beneficial for me. I saw the various procedures, processes and
equipment used in production of electricity by thermal powers which were studied in
books and this has helped me in better understanding of power generation.

S.T.P.S. is a very large plant and it is very difficult to acquire complete knowledge
about it in a short span. I have tried to get acquainted with overall plant functioning
and main concepts involved therein. The scope of Mechanical engineering is
increasing day by day. It is a vital trade.

During training I was permitted to take training at many section of mechanical

( Boiler and maintenance, turbine , fan, Air pre heater, coal handling plant, water
treatment plant, DM plant, coal mills) and general plant familiarization. I have
summarized all the things, which I saw & learned at S.T.P.S. in this training report.

Thermal power station

A thermal power station is a power plant in which the prime mover is steam
driven.Water is heated, turns into steam and spins a steam turbine which either
drives an electrical generator or does some other work, like ship propulsion. After it
passes through the turbine, the steam is condensed in a condenser and recycled to
where it was heated; this is known as a Rankine cycle. The greatest variation in the
design of thermal power stations is due to the different fuel sources. Some prefer to
use the term energy center because such facilities convert forms of heat energy into
electrical energy.
 SURATGARH SUPER THERMAL POWER STATION

Suratgarh Super Thermal Power Station is owned by Rajasthan Rajya Vidhyut

Utpadan Nigam Ltd. and is situated near village Raiyanwali about 25 KM from
Suratgarh town, an ideal location for setting up a thermal power station in the state
having regards to the availability of land, water, transmission network proximity to
broad gauge railway and being an important load centre for north west Rajasthan.
The techno-economic clearance for the prefect was issued by CEA in June 1991 –
the planning commission accorded investment sanction for the project in Nov. 91 for
a total estimated cost of Rs. 1253.31 crores on prices prevailing in Sept. 1990. The
updated cost of the project is estimate at Rs. 2300 crores of including IDC.

It has generation capacity of 1500 MW and installed with six Units of 250 MW each.
It is a coal base thermal station. Water and coal required in a large amount. Coal is
received here from coal-fields of MP areas through railways and water is received
from INDIRA GANDHI CANAL. The supply of coal is from MP, Jarkhand by rail.
About 18000 tonne coal required per day for whole unit and each unit consumes 150
tonnes coal per day.

About 2x3 km2 area covered by plant and approximately 1800 employees works in a
plant including chief engineer to labour. The supply electricity to the northern
Rajasthan, Ratangarh, Bikaner, Ganganagar.

FUTURE EXPENSION

It has been decided to set up 2 X 660 MW super critical units (Unit # 7 & 8) at
SSTPS. For this purpose about 446 Hectare land has been identified adjacent to the
existing 6 X 250 MW plant. This land is under process of acquisition. M/s TEC have
been appointed consulting engineers for this project. The state Govt. has also
accorded its inpriciple approval for setting up in future, two additional units of 2 X 660
MW (Unit # 9 & 10) also based on super critical technology.
 Installed capacity
Following is the unit wise capacity of the plant:

Stage Unit Number Installed Capacity (MW) Date of Comisioning Status

Stage I 1 250 May, 1998 Running
Stage I 2 250 March, 2000 Running
Stage II 3 250 October, 2001 Running
Stage II 4 250 March, 2002 Running
Stage III 5 250 June, 2003 Running
Stage IV 6 660 May,2010 Future
 ACKNOWLEDGEMENT

It is my proud privilege to express my sense of gratitude to Mr. Anil Dhawan (AEN)

for providing me adequate facilities to undergo training at S.T.P.S.
I have in particular to
appreciate the effort and keen interest taken by Mr. D. K. Nadheria (XEN), Mr. N. C.
Jain (AEN), Mr. N. K. Jain (XEN) and Mr. Deepak Tater (JEN) for their kind help and
assistance in under standing the working of diff. Equipment and for their kind
guidance during the period of training.
I am also grateful to Mr. Jangid (TA C&I) for their
persistent help and for providing some of the technical data in form of computer
print outs.
Last but not the least I am equally obliged to all those engineers
technical personnel and operators at S.T.P.S. who gave me their valuable time and
rendered practical knowledge in my training period.
And at last I want to thank my colleagues. Without their help guidance and
suggestions it was not possible to produce this training report.
 STEAM TURBINE

Introduction:

Steam turbine is a rotating machine which CONVERTS HEAT ENERGY OF

STEAM TO MECHANICAL ENERGY.
In India, steam turbines of different capacities, varying from 15 MW to 500
MW, are employed in the field of thermal power generation.

Basic principles:
The Thermal Power Plants with steam turbine uses Rankine cycle. Rankine cycle is a
vapour power cycle having two basic characteristics:
1. the working fluid is a condensable vapour which is in liquid phase during part
of the cycle and
2. The cycle consists of a succession of steady flow processes, with each
processes carried out in a separate component specially designed for the
purpose. Each constitute an open system, and all the components are
connected in series so that as the fluid circulates through the power plant each
fluid element passes through a cycle of mechanical and thermodynamic
stages.
The turbine is of tandem compound design with separate HP, IP and LP cylinder.
The HP & IP turbines are of single flow type while LP turbine is of double flow type;
the turbine is condensing type with single reheat. It is basically engineered on
reaction principle with throttle governing. The stages are arranged in HP, IP and LP
turbines, driving alternating current full capacity Turbo generators.

Specification

Type - tandem compound condensing

Reaction
Rated output of turbine - 250 KW
Rated speed - 3000 RPM
Main steam temperature - 537 C
Rated pressure - 150 kg/cm
 TURBINE COMPONENTS
Casing or Cylinders:
A casing is essentially a pressure vessel which must be
capable of withstanding the maximum working pressure and temperature that can be
produced within it. The working pressure aspects demand thicker and thicker casing
and the temperature aspects demand thinner and thinner casings.
1. H.P Turbine Casing: The principal parts of the HP turbine casing are and
axially split inner shell, enclosing the rotor and outer shell of a barrel-type
construction. The barrel type of cylinder construction ensures symmetry of the
wall thickness around the axis of rotation and hence the wall thickness itself is
relatively less than that used in other type of construction.
2. I.P. Turbine Casing: The IP turbine is split axially and is of single shell
design. The outer casing accommodates a double flow inner casing. The
steam coming from the reheater is passed into the inner casing via admission
branches which are symmetrically arranged in the top and bottom halves of
the outer casing.
3. L.P Turbine Casing: The LP turbine is of double flow type. The casing is of
triple shell, fabricated construction. The outer casing consists of the front and
rear end walls, two longitudinal girders and a top cover. The inner shell of the
inner casing acts as the guide blade carriers for the initial stages of the
turbine. The guide blade carriers of the LP stage groups are so designed that,
together with the inner casing, they form annular ducts which are used for
extractions.
.
Turbine governing system
The main purpose of governor is to maintain this desired
speed of turbine during fluctuations of load on the
generator by varying steam input to the turbine.
The governing system in addition to ensuring the falling
load-speed characteristics of the turbine also ensures the
following functions:

1. The run up the turbine from rest to rated speed and

synchronizing with the grid.
2. Meeting the system load variations in a predetermined manner, when running in
parallel with other machines.
3. Protecting the machine by reducing the load or shutting off completely in
abnormal and emergency situations.

The governing system also includes other devices to protect the turbine from
abnormal condition that may arise during operation.
In STPS By-pass Governing is used.

By-pass Governing:
In this system, in general, the steam is supplied through a
primary valve and is adequate to meet a major fraction of the maximum load
which is called economic load loads less than this, the regulation is done by
throttling steam through this valve. When the load on the turbine exceeds this
economic load which can be developed by the unthrttole full flow through the
primary valve, a secondary valve, is opened and throttled steam is supplied
downstream, bypassing the first stage and some high-pressure stages. This
steam joins the partially spent steam admitted through the primary valve,
developing additional blade torque to meet the increased load.

Governing of Reheat Turbine

In reheat turbines in cases of partial of full load ow off even
after the HP control valves are fully closed the entrained steam in the reheaters
and hot reheat line is more than enough to speed up the turbine above over speed
limits. Hence it is necessary to provide stop valves and interceptor valves on hot
reheat line before IP turbine. While the stop valve is operated controlled similar to
HP control valve but at a higher speed range by a secondary of pre-emergency
governor as it is called. The valve remains full open at rated speed and starts
closing at about 3% overspeed and is fully closed at about 5% over speed.

1. , the surface friction and the turbulence set up in the oil.

BOILER

Introduction
The boiler is the main part of any thermal power plant. It converts the fuel energy into
steam energy. The fuel may be furnace oil, diesel oil, natural gas or coal. The boilers
may be fired from the multiple fuels.
The boiler installed in S.T.P.S. are made by M/s BHEL . Each of the boilers are single
drum, tangential fired water tube naturally circulated over hanged, balanced draft,
dry bottom reheat type and is designed for pulverizing coal firing with a max.
Continuous steam output of 375 tons/hour at 138 kg/cm2 pressure and 540 degree
cent. Temp. The thermal efficiency of each boiler at MCR is 86.8 %. Four no. Of bowl
mills have been installed for each boiler. Oil burners are provided for initial start up
and stabilization of low load .Two E.S.P. (one for each boiler) is arranged to handle
flue gases from the respective boilers. The gases from E.S.P.are discharged through
180 meters high chimney. I.D. fan and a motor is provided near the chimney to
induce the flue gases.

CIRCULATION SYSTEM:

It is essential to provide an adequate flow of water and/or of

water-steam mixture for an efficient transfer of heat from furnace to the working fluid
and to prevent ‘burn-outs’. This is irrespective of the mode of circulation being used.

In STPS NATURAL type of circulation system are used.

Natural Circulation:
In this type, no external pumping device is used for the movement of the fluid.
The difference in densities in contents of fluids in down comers from the drum and
risers in the furnaces is used to effect the movement of fluids. This type of circulation
is employed in most of the utility boiler.

The movement of the steam and water will increase with increased heat input
to a maximum value or so called end point, after which further increase in heat
absorption will result in a decrease in flow.
One of the characteristics of natural circulation is its tendency to provide the highest
flow in the tubes with the greatest heat absorption.

Heat Transfer in Boiler:

In boiler heat energy is released from the combustion of fossil fuels and the
heat is transferred to different fluids in the system and a part of it is lost or left out as
unutilized.

There are three modes of heat transfer :

• Conduction
• Convection
• Radiation
 Heat energy is transferred from a heat source to a heat receiver by one or
more of these modes for which heat source should be at a higher temperature than
the receiver.

In superheater tube with high temperature region but does not directly view
the flame. Here the heat is transferred from flue gas to superheater tube metal by
convection and by non-luminous radiation and in the tube metal by conduction and to
the steam by forced convection.
The power plant boilers are large capacity steam generators used purely for
the electrical power generation.
 BOILER PRESSURE PARTS

Economizer:
Economiser is a feed water heater.It uses the heat produced by the flue gases for
this purpose.The feed water is passed through the economiser before supplying it to
the boiler and economiser absorbs a part of heat from the flue gas to increase the
temperature of the feed water.
Super heater:
The steam produced in the boiler has got moisture content so it is dried and
superheated (ie steam temperature is increased above boiling point of water)by the
flue gases on the way to chimney.Super heating ensures two benefits at first the
overall efficiency of the system is increased and secondly the corrosion to the turbine
blades due to condensation in later stages is prevented.The superheated steam from
superheater is fed to steam turbine by means of a main valve.

Steam Flow:
Saturated dry steam from the drum follows the course that is:
Steam cooled wall roof tubes –steam cooled side wall tubes – extended steam
cooled side wall tubes – front steam cooled wall tubes – steam cooled roof and
rear wall tubes- super heater rear horizontal assemblies – super heater de-super
heater- platen super heater – pendant super heater.
Super heated steam from the pendant super heater outlet header goes to the
turbine via the main steam lines.
After passing through the high-pressure stages of the turbine, steam is returned
to the re-heater via the cold reheat lines. The reheat de-super heaters are located
in the cold reheat lines.
Reheat flow through the unit is as follows:
Front pendant re heater – rear pendant re-heater.
After being reheated to the design temperature, the reheated steam is
returned to the low-pressure section of the turbine via the hot reheat line.

Reheater:
Reheater are provided to raise the temperature of the steam from which part
of energy already been extracted by HP turbine.
The reheater is composed of two stages or section, the front pendant vertical
spaced platen section and the rea5r pendant vertical spaced platen section.
The rear pendant vertical spaced section is located above the furnace arch
between the water- cooled screen tubes and rear water wall hanger tubes.
The front pendant vertical spaced plated section is located between the rear
waterwall hanger tubes and the superheated platen section.
All reheater drains and vents are opened before lighting off. The vents and
drains to the atmosphere must be closed prior to raising a vacuum in the condenser.
Drains connecting with the condenser may be lift open until the boiler is under light
load
Water Cooled Furnaces:

Bharat Heavy Electrical Limited has developed the modern water-cooled furnace.
Furnace is the primary part of boiler where the chemical energy available in the fuel
is converted to thermal energy by combustion. Furnace is designed for efficient and
complete combustion. Major factors that assist for efficient combustion are time of
residence (fuel) inside the furnace, temperature inside the furnace and turbulence
which causes rapid mixing between fuel and air.
It has following Advantage:
• In furnace not only combustion but also heat transfer is taking place
simultaneously.
• The maintenance work involved in repairing the fire bricks is practically
eliminated.
• Due to heat transfer in the furnace the flue gas leaving the furnaces is
reduced to the acceptable level to the superheating surfaces.

Soot Blowers:

Steam has mainly been used as the soot blowing medium, but recently the
used low-pressure air as a soot blowing medium has been introduced as this offers a
number of advantage.
 AIR AND GAS PATH

General:
The total air flow through the unit is handled by two numbers axial reaction
forced draft fans and two numbers axial reaction primary air fans. The flue gas
produced in the furnace from combustion of fuel is evacuated by two numbers radial
double suction Induced draft fans. The schematic of air and flue gas system is
enclosed.

Air System:
1. Combustion Air (Secondary Air) : The forced draft fans supply the
required secondary air for combustion.
This air is preheated by two no. RPAH. Control of secondary air flow is done by
FD fan blade pitch control. The distribution of hot secondary air to the wind box
compartments is controlled by “Secondary air dampers”.

2. Air for Drying and Transportation of pulverized coal (Primary Air) : The
cold primary air fans supply the air required for drying the coal in the tube
mills/mixing box and for transporting the pulverized fuel from both ends of the
tube mill to the coal burners. The primary air is heated in the primary sectors
of the Rotary RAPH.
The control for the primary air pressure is achieved through PA fan inlet
dampers.

3. Scanner Cooling Air : Each boiler is provided with 20 no. VISIBLE LIGHT
SCANNER. The two no. of scanner air fans are provided to supply the
required air for cooling these flame scanners. The supply of air is taken from
FD fan discharge. The air is filtered and boosted to the required pressure by
the scanner air fans. Additionally an emergency air supply connection from
atmosphere is provided for supplying the cooling air to the scanners in case
both FD fans trip.

4. Seal Air: Six no. of seal air fans are (2 nos. per mill) are provided for each
boiler. The sealing air is required for mill trunounim mill discharges valves and
gravimetric feeders, of the two seal air fans provided for each tube mill, one is
in operation and the other standby. The seal air takes suction from the
atmosphere.

Gas system:
The flue gases produced in the furnace as a result of combustion,
travels upward in the furnace, across the horizontal pass and downward through
the second pass of the boiler to the air preheater.
 Two no. of Induced draft fans are provided to evacuate the flue gas
from furnace to the chimney. The ID fans are provided with hydraulic coupling and
inlet damper control.

PRESERVATION OF BOILERS
Atmospheric corrosion of ferrous materials proceeds rapidly in the presence
of oxygen and moisture. The oxides produced are objectionable and can be
transported to critical heat transfer areas as well as to the turbine. Pit type corrosion
can also occur in walls. In large boilers, with numerous complex circuits and bends, it
is practically impossible to completely dry the boiler in preparation for storage.
 Fuel Oil Burning System

Fuel Oil Atomization:

Atomizes the process of spraying the fuel oil into fine mist, for
better mixing of the fuel with the combustion air. While passing through the spray
nozzles of the oil gun, the pressure energy of the oil converts into velocity energy,
which breaks up the oil stream into fine particles. for satisfactory atomization the
viscosity shall be less than 15-20 centistokes.

HEA Ignitors:
HEA Ignitors are provided in this Boiler. This ignitor uses
LFO/HFO as main fuel and this is ignited using spark and is mounted adjacent to
oil gun.

Air Cooled Oil Guns:

The atomized assembly of an operating oil gun is protected from
the hot furnace radiation by the flowing fuel oil and steam which keeps it relatively
cool. The oil gun assemblies supplied for this project have been designed for air
cooing provision.

Burner Trip Valves:

To control the atomizing medium and fuel flow to the oil guns,
pneumatic operated trip valves are used.

Main Parts of Boiler:

1. The boilers consist of the following main parts:
2. Forced Draft Fan (FDF)
3. Air Preheater (RAH)
4. Burners
5. Furnace
6. Up Rise Tubes
7. Down Comer Tubes
8. Water Tubes
9. Super Heaters
10. Gas Recirculation Fan (GRCF)
11. Re-Heater
12. Induced Draft Fan (IDF)
AIR PREHEATER
Air preheater is a heat exchanger in which air temp. is raised by transferring heat
from other fluids such as flue gas . Since air heater can be successfully employed to
reclaim heat from flue gas at lower temp. level ,then it is possible with economizer the
heat ejected to chimney can be reduced to a great extent thus increasing the efficiency
of a boiler.

Specification
1. Heating element - Hot end, Hot intermediate, Cold end
Materials - Carbon & Corten steel
2. Rotor main drive motor - 11 kW, 1450 rpm, 50 Hz
Coupling - Fluid coupling 11.5 fcu
2. Bearing
Guide bearing : Spherical roller bearing
Support bearing : Spherical roller thrust
Thermostat: Burling thermostat
3. Oil capacity
Guide brg. Housing : 25 lt.
Support Brg. Housing: 150 lt.
4. Steam Coil Airpreheater
Number of steam Coil APH : 2 Nos per boiler
Installed position : Vertical
Design Pressure: 20 kg/cm2
Design Temperature: 2500C
Weight of One steam coil APH: 1950 kg.
 CONDESER
The functions of condenser are:
1. To provide lowest economic heat rejection temperature from the steam. Thus
saving on steam required per unit of electricity.
2. To convert exhaust steams to water for reuse this saving on feed water
requirement.
3. Deaeration of make-up water introduced in the condenser.
4. To form a convenient point for introducing makes up water.

IN STPS RVUN SURFACE CONDESER is used.

Surface Condenser:
This type is generally used for modern steam turbine installations.
Condensation of exhaust steam takes place on the outer surface of the tubes, which
are cooled by water flowing inside them.
The condenser essentially consists of a shell, which encloses the steam space. Tubes
carrying cooling water pass through the steam space. The tubes are supplied cooling
water form inlet water box on one side and discharged, after taking away heat form
the steam, to the outlet water box on the other side.
Instead of one inlet and one outlet water boxes, the may be two or more pair of
separate inlet-outlet water boxes, each supplying cooling water to a separate bundle
of tubes. This enables cleaning and maintenance of part of the tubes while turbine
can be kept running on a reduced load.

Description of condenser
The condenser group consists of two condensers, each connected with exhaust part
of low pressure casing. A by-pass branch pipe has interconnected these woe
condensers. The condenser has been designed to create vacuum at the exhaust of
steam turbine and to provide pure condensate for reusing as feed water for the
boilers. The tube layout of condenser has been arranged to ensure efficient heat
transfer from steam to cooking water passing through the tubes, and at the same
time the resistance to flow of steam has been reduced to the barest minimum.

350% capacity condensate pumping sets are installed for pumping the condensate
from condenser to the deaerator4 through low-pressure heaters. Two pumps are for
normal operation and one works as stand by pump.

Materials for Condenser tubes

Selection of tube material mainly on the quality of cooling water and the
cost. Coppers alloys are preferred as copper has very high heat transfer coefficient.
But as copper has very little mechanical strength; it has to be reinforced by alloying
with other metals.
Stainless steel tubes has also been used and has good corrosion resistance though
heat transfer coefficient is quite lower ht an the copper alloy.

Regenerative Feed Heating System

If steam is bled from a turbine and is made to give up its latent and any superheat it
may possess, to a heater this system is called regenerative, because the fluid gives
up heat, which would be otherwise wasted, to the fluid whilst in another state to raise
its temperature. The highest theoretical temperature to which the feed water may be
raised in the heater is the saturation temperature of the bled steam. There is an
optimum point at which the steam is bled form the turbine once a feed temperature is
selected, a tapping point near the stop valve produces no gain in efficiency as
practically live steam is used for heating.

Regenerative system of 250 MW unit

The regenerative system of the turbine consists of four low-pressure heaters, two
gland coolers, one deaerator and three high-pressure heaters. The condense is
drawn by condensate pumps from the hot well of condenser and is pumped to the
deaerator through gland coolers and low pressure heaters where it is progressively
heated up by the steam extracted from seals and bled points of the turbine. The drain
of condensate steam on LP heaters No. 2,3 and 4 flows in cascade and is ultimately
pumped into the main condenasate line after heater No.2 or flows to condenser. The
feed water after being deaerated in the deraerator is drawn buy the boiler feed pump
and pumped to boiler through high pressure heaters where it is heated up by the bled
steam from the turbine. The drain of condensed steam of HP heaters flows in
cascade and under normal load conditions flows to the deaerator.
 HP-LP BYPASS SYSTEM

This bypass system has been provided to allow the steam generator to build up,
during start-up, matching steam parameter with the tribune. The steam generated is
dumped into the condenser, thus avoiding loss of boiler water. This system enables
starting of he unit of sliding parameters and also facilitates hot restarting of the unit.
In the event of loss of load on the turbine, the bypass system disposes the steam
produced by; the boiler automatically to he condenser without affecting the boiler
operation.
The bypass system had two sections: HP & LP. The HP-Bypass system diverts the
steam before main steam valve to he cold reheat CRH line. HP Bypass system also
reduces the rated steam parameters of the incoming steam from the superheated to
the steam condition expected in the CRH line (i.e. steam temp. and pressure after
HP turbine exhaust).
The LP Bypass diverts the incoming steam from hot reheat line before intercepting
valves to he condenser after reducing the HRH steam parameters to the conditions
approximately to that of LP steam turbine exhaust steam.

HP Bypass station is utilised for the following tasks:

1. To establish flow at the outlet of superheated for raising boiler parameters during
starts up.
2. To maintain or controls steam pressure at pre-set value in main steam line during
start up.
3. To warm up the steam lines.
4. To control steam temperature down of HP bypass at the reset value

LP Bypass station is utilised for the following tasks:

1. Control of steam pressure after reheater.
2. Establish flow of steam from reheat lines to condenser by its opening,
proportional to the opening of HP bypass valves.

• DEAERATER
Condensate from hot well is pumped to de aerator by
condensate extraction pump. Functions of de aerator are: -
1. Removal of dissolved air/oxygen in boiler water.
2. Chemical dosing for maintaining quality of boiler water.
3. Regenerative heating of feed water for increasing its temperature
and efficiency of plant.
4. Storage of feed water in water/steam cycle.

Booster Pump
WORKING:
50 % tandem boiler feed pump sets are supplied to this contact, three pump sets for
each boiler. Two sets are run in parallel, supplying each boiler, with one pump set
being on stand-by.
Each pump set consists of a “FA1856” booster pump, directly driven form one end of
the shaft of an electric driving motor, and a “FK6D30’ boiler feed pump driven from
the opposite end of the motor shaft through a variable speed turbo-coupling. The
drive is transmitted, in each case through a spacer type flexible coupling.
The bearings in the booster pump and pressure stage pump and in the motor are
lubricated from a forced lubricating oil system incorporated in the turbo coupling.
The booster pump is a single stage, horizontal, axial split casing type, having the
suction and discharge branches on the casing bottom half, thus allowing the pump
internals to be removed without disturbing the suction and discharge pipe work of the
alignment between the pump and the motor.
The pump shaft is sealed at the drive end and the non-drive end by mechanical seals
which are flushed by a supply of clarified water.

TECHNICAL DATA:

Pump type : FA1856

Direction of rotation : Anti - clockwise
(Viewed from drive end)
Liquid pumped : Boiler Feed Water
Suction temp. : 161.10C
Flow rate : 490 m3/hr.
Efficiency : 81 %
Input power : 151 KW
Speed of pump : 1485 rpm

Components of Booster Pump:

• Pump Casing
• Rotating Assembly
• Journal and Thrust bearing
• Bearing Housing
• Mechanical Seals
• Motor / Pump Casing

Boiler Feed pump

WORKING:

The FK6D30 type Boiler Feed Pump is a six stage, horizontal centrifugal
pump of barrel casing design.
The pump internals are designed as cartridge which can be easily removed
for maintenance without disturbing the suction and discharge piping work
or the alignment of the pump and the turbo coupling.
The pump shaft is sealed at the drive end and non-drive end by
mechanical seals, each seal being flushed by water in a closed circuit and
which is circulated by the action is cooled by, [assign through a seal
cooler, one per pump, which is circulated with clarified cooling water. The
rotating assembly is supported by plain white metal lined journal bearings
and axially located by a Glacier double tilting pad thrust bearing.

TECHNICAL DATA:

Pump type : FK6D30

No. of stages : 6
Direction of rotation : Anti – clockwise
(Viewed form drive end)
Suction temp. : 161.10C
Design flow : 490 m3/hr.
Efficiency : 81 %
Speed : 5310 rpm
Input power : 3322 KW
Drive Motor
Manufacturer : B.H.E.L., Haridwar
Rating : 3550 KW
Speed : 1492 rpm
Electrical supply : 6.6 kv, 3-ph, 50 Hz

Components of Boiler Feed Pump:

• Pump Casing
• Discharge Cover
• Suction Guide
• Ring Section Assembly
• Mechanical Seal
• Journal and Thrust bearing
 • Bearing Housing
• Hydraulic Balance
• Flexible Coupling
The lubricating oil for the journal and thrust bearings, of the booster pump and boiler
feed pumps and the drive motor will be supplied form the lubrication oil system
associated with the hydraulic coupling and should be as follows:

Condensate Extraction Pump

Technical Specification:

Type : EN 8 H 32
Direction of rotation viewed : Clock-wise
Suction temp. : 46.10C
Sp. Gravity : 0.9901
Speed : 1485
Power absorbed : 266 KW
Efficiency : 78 %

WORKING:

The condensate Extraction Pumps are of the vertical, eight stage, Centrifugal
canister type, with the driving motor supported on a fabricated head piece and the
eight inter connected pump stage are suspended below the head piece. The pump
discharge branch and suction branch are formed on the head piece above floor level.
The eight pump stages are contained within a fabricated canister, and each stage
casing is located by spigot and secured together with bolts, nuts and lock washer.
The canister is suspended and secure to a foundation ring with screws. The head
piece is also secure to the canister with screws.
Each pump directly driven through a flexible coupling by a 325 KW electric motor.

Components of Condensate Extraction Pumps:

• Head piece
• Foundation Ring
• Canister
• Stuffing Box Assembly
• Thrust and journal bearing assembly
• Coupling
• Driving motor
In SURATGARH THERMAL POWER PLANT, there are three
fans:

1. F.D.FAN (Forced fan)

2. I.D.FAN (Induced fan)
3. P.A.FAN (Primary fan)

Forced Draft Fan

In the Axial Reaction Fans (Type AP), the major part of (about 80 %) energy
transferred is converted into static pressure in the impeller itself. The rest of the
energy is converted into static pressure in the diffuser. These fans are generally
driven at constant speed. The flow is controlled by varying the angle of incidence of
impeller blades. It therefore becomes possible by this process to achieve high
efficiencies even during part load operation.
The blade pitching operation is performed by mechanical linkages connected to a
hydraulic servomotor which is flanged to the impeller.

Technical Data:
Application : Forced Draft Fan
No. off : 2
Medium handled : Atmospheric Air
Orientation : Vertical Suction and
Horizontal Delivery
Capacity : 105.2 m3/Sec
Temp. Of medium : 450C
Speed : 1480 rpm
Coupling : Rigiflex coupling
Drive motor
Rating : 700 KW
Speed : 1480 rpm
Fan Weight : 8 Tones

Type of fan regulation : Blade Pitch Control

When looking in flow direction, the fan consists of the
following Components:
• Suction chamber
• Fan Housing
• Rotor Consisting go shaft, one impeller with adjustable blades with pitch
control mechanism.
• Main bearings (Antifriction bearings)
• Outlet Guide Vane housing with guide vanes
• Diffuser

Fan Accessories:
Rigiflex Shaft Coupling:
The fan shaft is connected to the motor shaft by means of
Rigiflex couplings.
Oil Circulation System :
The oil system consists of an oil tank, two pumps(on Stand by),
filters, coolers and necessary fitting.
Drive Motor:
These fans are driven by constant speed Synchronous Induction
motors.
Silencer:
These fans are provided with a silencer to attenuate.
Airborne noise to acceptable level.

Lubrication:
The lubrication oil for the fan bearings ate supplied by the
centralized oil pumps which supply oil for the hydraulic servo meter also.
Recommend Oil:
Servo Prime - 68 of IOC
Turbinal - 68 of HPC
 INDUCED DRAFT FAN
Radial fans manufactured are single stage, single/ double suction, simply
supported/overhung centrifugal machine which can be used to handle fresh air as
will as hot gases in power plant application.
In this, the medium handled enters the impeller axially and after passing
through the impeller leaves radially. A large part of the energy transferred to the
medium is converted into kinetic energy as the medium passes through the
impeller. The spiral casing converts part of the kinetic energy in the medium to
pressure energy. These fans are generally driven by constant speed motors. The
output of the fan is usually controlled by inlet dampers or inlet guide vanes or by
varying the speed of the fan by suitable speed control device.

Technical data:
Application : Induced Draft Fan
No. off : 3
Type : NDZV 33 S
Medium handled : Flue Gas
Orientation : 450 Top incl. Suction
Bottom Horizontal,
Delivery
Capacity : 250.5 m3/Sec
Temp. of medium : 1540C
Speed : 740 rpm
Coupling : Hydraulic Coupling
Drive motor
Rating : 1750 KW
Speed : 740 rpm
Fan Weight : 52.7 Tones

The major sub-assemblies of the fan are as follows:

• Impeller with shaft assembly

• Bearings and thermometers
• Suction chamber and spiral casing
• Flow regulation devices
• Shaft seals
• Couplings
• The fan is drive by an electric motor.

• The fan bearings are lubricated by means of oil

lubrication. The oil must not foam during operation. Foam removing
agents containing silicon must not be utilized. The oil must have good
anti-corrosion properties.

PRIMARY AIR FAN

PA Fan is same as forced draft fan. Only the differences is that in this fan there are
two stages AP fan(Axial Profiles fan), the two impellers are connected by means of a
link rod, with this we can operate both the impeller blades synchronously.

Technical data :
Application : Primary Air Fan
No. off : 3
Type : AP 2 17/12
Medium Handled : Atmospheric Air
Speed : 1480 rpm
Rating : 1400 KW
Fan wt. : 10.8 tones

E.S.P.
E.S.P THEORY

E.S.P. is a highly efficient device for extraction of

suspended particles and fly ash from the industrial flue gases.

WORKING PRINCIPLE :

E.S.P can handle large volume of gases from which solid particles
are to be removed Advantages of E.S.P. are :- High collection efficiency Low
resistance path for gas flow Treatment of large volumes at high temp.Ability of cope
with corrosive atm.An E.S.P. can be defined as a device which utilized electric
forces to separate suspended particles from flue gases WORKING STEPS :
Ionization of gases and charging of dust particles Migration of dust
particles. Deposition of charge particles on collector surface. Removal of paE.S.P.
consist of two sets of electrodes, one in the form of thin wire, called discharge or
emitting electrode in the form of plates. The emitting electrodes are placed in the
center or midway between two plates and are connected to-ve polarity of H.V. D.C
source of order of 37 KV collecting electrodes are connected to + ve polarity. The
voltage gradient between electrodes creates “CORONA DISCHARGE”, Ionizing
the gas molecules. The dust particles present in flue gases acquire -ve charge and
deposited on collecting electrodes. The deposited particles are removed by knocking
the electrode by a process called “RAPPING’ DONE BY “ RAPPING
MOTORS”.
Cooling Towers:
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove
process heat and
cool the working fluid to near the wet-bulb air temperature or rely solely on air to cool
the
working fluid to near the dry-bulb air temperature. Common applications include
cooling the
circulating water used in oil refineries, chemical plants, power stations.
Cooling Water Pump:
The motor of the CWP has following specification;

Type: Y1600-16/2150
Out Put Power: 1600KW
Stator Voltage: 6.6KV
Speed: 372rpm
Frequency: 50Hz
Stator Rated Current:182A
Stator Connection: 2Y
Ambient Temperature: 50C
Insulation Class B
Weight 17500Kg
CW Pump:

Type is single stage double suction centrifugal pump

Type: 1400S25-1
Capacity: 16000m3/H
Speed: 370rpm
Power : 1600KW
Weight : 35000kg
Head : 25m
NP SHR : 8.5m
 COAL HANDLING PLANT
Wagon tippler has rated unloading capacity of
twelve box wagon per hour, including shunting and spotting
time of haulage equipment.
For vibrating feeders of capacity 350 tons/hr.
each have been provided feeding unloads coal. A steel
hopper has been provided in crusher house to receive coal
and distribute it through manually operated rack and pinion
gate to three vibrating screens of 675 t/hr. capacity each
coal above 200 mm size passes on granules for crushing
and reduction in size. Coal below 20 mm size passes
granular and discharged on to crushed coal conveyor belt.
Following permutation and combination of
operation are possible with installed system. To transfer all
crushed coal received from crusher house to live storage
pipe. To transfer part of received crushed coal to plant and
to balance to storage yard. To deliver the raw coal bunkers
part and received crushed coal mixed with balanced coal
from the live storage pipe. To transfer the plant crushed
coal at 750 T/hr from the reclaim live pile and
simultaneously stock and s/ road. the vibrating ones as
stated above can be obtained by the use of flap gates
which are installed on various chute and two vibrating
feeders, installed on tower. The coal carried on various
conveyers shall be main monitored to ensure proper
loading and distributing weightless and vibrating feeders.

ASH HANDLING PLANT

The ash handling system provide for
continuous collection of bottom ash from the furnace hearth
and its intermittent removal by hydro ejectors to a common
slurry sump. It also provides for removal of fly ash to the
common slurry sump. Each boiler is provided with ash
precipitator for collecting the fly ash from the flue gases
with high efficiency of collection to minimize the dust mains
and to reduce the wear of induced draft fan. The fly ash
separated from flue gases in the ash precipitator is
collected in hoppers at the bottom from where it is mixed
with water to form slurry and disposed off to pumping area
by means of hydro ash pumps. Bottom ash from the boiler
furnace is passed through slag crushers and then slurred to
the slurry chamber at the suction of the ash disposal
pumps. These are high pressure and low pressure pumps
for this purpose. At a time one pump is working and other
two are stand by. From the ash disposal pump house ash
slurry is pumped through pipe lines to the ash dump area
within about 1.5 km away from the ash disposal pump
house. Too separate discharge lines are provided one for
each unit but only one line is used. The ash slurry from the
two units is taken in one discharge line through electrically
operated valves.

WATER TREATMENT
INTRODUCTION:
The natural water contains solid,
liquid and gaseous impurities and therefore, this water
cannot be used for the generation of steam in the boilers.
The impurities present in the water should be removed
before its use in steam generation. The necessity for
reducing the corrosive nature & quantity of dissolved and
suspended solids in feed water has become increasingly
important with the advent for high pressure, critical &
supercritical boilers.

IMPURITIES IN WATER:

The impurities present in the feed water are classified as

given below –

1. Undissolved and suspended solid materials

• Turbidity and Sediment
• Sodium and Potassium Salts
• Chlorides
• Iron
• Manganese & Silica

2. Dissolved Salts and Minerals

• Calcium and Magnesium Slats

3. Dissolved Gases
• Oxygen
• Carbon Dioxide

4. Other Materials
• Free Mineral Acid
• Oil

RAW WATER AND IMPURITIES:

 Source:
The various sources of water can be broadly
classifies as:
a) Rain water
b) Surface water (Rivers, Streams, Ponds,
Lakes)
c) Ground water ( Springs, Shallow wells and
Deep Wells)

Impurities:

The major impurities of water can be classified in

three main groups are:
Non- ionic and Undissolved :
These are mainly turbidity, slat,mud,
dirt and other suspended matter

1. .Ionic and Dissolved

2. Gaseous Impurities : Carbon Dioxide
and Oxygen

Removal Of Impurities:
Our major concern
is industrial water treatment, whereby, water used directly
or indirectly in an industrial process is made suitable for
that particular application. The use of water in boilers fro
steam generation is an obvious industrial use. Depending
on the process, varying degrees of purity of treated water
are required. For example, a textile processing unit will
require soft and clear water for process use: a chemical
plant or electronic components manufacturing unit will
require ultra-pure water containing total dissolved impurities
not exceeding 0.5mg/litre or less.

MILLING PLANT
Pulverized coal Systems:
For steam generation, there is
basically system of pulverization normally in STPS plant
used is Direct Firing System
Direct Firing System:

1. Hot Primary System:

In this system the fan is located

before the pulverized and handles complete primary air
required for drying a transporting the coal. Disadvantages
are that the fan is required to handle high temperature air
resulting in high a fan power. Separate sealing air fans are
required to seal the mill and Journal bearings.

2. Cold Primary Air System:

The primary air fan handles clean

cold air either from FD fan discharge or taking suction from
atmosphere. The advantages are saving in fan power and
maintenance. The only disadvantage. Is the cost increase
due to additional duct work and air heater.

3. Suction System:

In this system the mill operates under

negative pressure. Suction being created by an exhauster
placed after the mill. The exhauster handles all the coal air
mixture and forces it into the burners. The advantage of
suction system is that the plant can be maintained clean.
The disadvantage of this system id that he high speed
exhauster has to handle coal air mixture and tends to wear
more as the pulverized size increase.

4. Pressurized Exhauster system:

In this system the mills operate under

positive pressure. With exhauster provided at hr exit of
pulverize to boost the pulverized coal into the pressurized
furnace. Since the pulverized operates with lesser pressure
than forced draft fan pressure.

In plant TUBE type of pulverized mill is

used.
 Drum/Tube mills:
This type mills is slow speed type.
They operate at a speed of 17-20 rev/min and formerly
were designed as suction mills.
The mill drum carrying the ball charge
rotate in the antifriction bearings. Raw-coal is fed to the
drum through the inlet elbow and gets crushed to powder
inside the mill drum. The ball charge and the coal are
carried to certain height inside the drum and slowed to fall
down. Due to the impact of the balls on cola particle sand
due to attrition as the particles slide over each other and
also over the liners, the coal gets crushed. Hot flue gases
are used for drying and transporting the pulverized coal
from the mill to the classifier.
As a result of this high availability in a
tube- ball mill installation, it is not normal to provide standby
milling capacity; this helps to reduce the overall capital cost
of the plant. Power requirements have also been reduced,
but they are still much greater than those for medium-
speed mills.

Advantage:

• High output possible, up to 50 tones per hour.

• No maintenance over long periods
• High availability
• Because of high availability no stand by capacity is
required
• No mill rejects, no problems with ‘tramp’ iron
• Reserve of fuel within mill makes output more stable.

Disadvantage:

• High power consumption

• Some problems with control of coal level
within the mill.
 • Virtually constant power consumption at all
loads; low load operation of therefore not
economical.
• With high moisture content fuels a high
primary air temperature is required because of the
low air /fuel ratio
• Unplanned stops leave the mill full of coal
which, under unfavorable conditions, can ignite. This
coal has to be quenched and even dug out
otherwise the mill cannot be restarted.

COAL FEEDERS
Coal feeders deliver the cola from the
bunkers to the mill. Since the amount of coal delivered
determines the output of the mill, if follows that the cola
flow, through the feeder has to be controlled. This is
normally achieved either by control of feeder speed or by
control of the position of a scraper knife or plough.

In plant Drag Link Coal Feeders type of

Coal Feeder is used.

Drag Link Coal Feeders:

In this type of cola feeder, the coal leaves the
bottom of the bunker through a large outlet hopper which is
connected directly to the feeder casing. The cola falls on
the feeder top plate and is dragged along by the conveyor
chain to the point where the top plate ends. The depth of
the cola bed is controlled by the height regulating gate. At
the end of the top plate the cola falls down between the
stands of the chains to the Point of discharge at the mill
inlet coal delivery chute. The rate of coal feeds controlled
by variable speed motor drive.

GENERATOR
Mechanical energy is converted into electric
power the stator windings of generator by the interaction of
rotating magnetic field. Rotating magnetic field is created
by field windings mounted on rotor shaft with the help of
excitation system. When the shaft is rotated at 3000 RPM
by the coupled turbine electric power is generated at a
voltage 16.5 KV and 50 HZ frequency. Generator is filled
with hydrogen gas for cooling its winding which in turn is
cooled by circulating water. The voltage of such generated
electricity is step up to 220kv or 400kv through transformer
and power transmitted to Ratangarh GSS for Northern Grid,
and different areas of Rajasthan.
6.0 million units energy is generated in 250 MW
unit in a single day, out of this about ten percent is
consumed in unit itself for running its auxiliary equipments
like pumps, fans etc. about 3300 metric tons of coal is
consumed in one 250 MW unit in one day.

THEORY
Turbo generator manefactured by BHEL in
Co-Operate with most modern design concept and
constructional features which ensures reliability, easy and
constructional and operational economicity.
There is a provision for cooling water in order to
maintain a constant temp. of coolant (hydrogen) which
controls the temp. of wdg., core etc as per loads.
Technical Data:
Apparent power 294MVA
Active Power 250 MW
Current 10290 Amps.
Voltage 16.5 kV+/- 825V
Speed 3000 rpm
Power Factor 0.85
Hydrogen Pr. 3.0 bar
Rated Field Current 2386 Amps
.

CONTROL AND
INSTRUMENTATION CIRCLE:
-
STPS have divided four sections in C&I (control &
instrumentation) Circle: -

1. SWAS package
2. FSSS package
3. ATRS package
4. DDC section
 SWAS [Steam Water Analasis System]: -
Steam Water
Analysis System is full form of SWAS. SWAS
package is use for analysis of steam sample which
coming from Boiler. There are coming nine lines
from the Boiler. These nine lines go in cooling
system for temperature
Maintain.
There are two types of cooling system, Primary
cooling system and Secondary cooling system. The
equipment is designed and assembled to enable
the conditioning of samples of Boiler water and
steam by reducing the temperature and pressure to
a suitable state to enable the chemical parameters
of the sample to be monitored.

Sample conditioning panel comprises: -

Line Numbers: -
1. Make up drum water
2. Conedensate pump
Discharge
3. LP Heater inlet
4. Feed water booster pump
5. Feed water economizer
inlet
6. Boiler drum water
7. Boiler saturated steam
8. Main steam
9. Hot well

BLOCK DIGRAM OF SWAS PACKAGE

Steam samples
Form Boiler

Primary Secondary Conditioning Dry

Cooling Cooling P&T Panel
There are different measurements of samples of steam: -

SODIMAT: - The measurement of sodium in

industrial ultrapure waters. The measurement is
based on a direct potentionetric technique.
Technique using highly sensitive sodium glass
electrode. The difference of potential between the
glass electrode and the reference electrode is
directly proportional to the sodium concentration.
Modern high-pressure
power plants require feed water of very high purity.
Safety in that sector is of great importance and the
sodium measurement plays a specific role
compared to pH, conductivity and silica trace.
Actu
ally sodium cations and anions are always linked.
Most cations have a corrosive influence in water
and vapor cooling circuits. Became of this chemical
link between sodium ions and anions, sodium
measurement presents particularly important risk
of corrosion and other effects. The SODIMAT uses
a sodium sensitive glass electrode to measure
sodium in a sample which has been previously
conditioned to a pH > 10.

HYDRASTAT: - low-carbon steel exhibits a

significantly improved resistance to corrosion it in
contact with water of high alkalinity (pH 9-10).
High – pressure circuits operating with the
alkaline reign, therefore employ volatile alkalizing
agents such as ammonia in combination with
hydrazine to elevate the feed water pH to a level >
pH 9.0.

The addition of hydrazine serves the dual function

of an alkalizing agent as well as on oxygen
scavenger thus lowering the level of corrosion. The
anodic dissolution of iron in low carbon steels is
nominal at ph 9.5 provided the totally
demineralized water is available ammonia
concentrations required to reach this high degree
of alkalinity would be detrimental to the copper
tubes of the condenser because of dissolution of
copper, thus imposing an upper limit of ph 9-9.3.

CONDUCTIVITY MEASURMENT: - The

electric conductivity measures the transport of
electric change in any field. In metal conductors
the current flows by transport of electrons where
as in solution. It flows by transportation such as
Na+ and Cl- which the higher transport of charges
is the conductance of the solution.
Conductivity is the capacity of a solution has
to conduct current: -
In solution conductivity is much more complicated
than in conductors because several species ensure
the transport of charge for instance in drinking
water the conductive species registered are
sodium, calcium, magnesium, ferrous cations,
ferrites, phosphates and nitrate ions for slightly
concentrated solution. The concentration of H+
protons and hydroxyl OH- ions can no longer be
neglected in the presence of the product this.
Therefore leads to a non-linear variation
conductivity/ concentration.

SILICOSTAT: - Hp turbine nozzles and blades

may, under the influence of high-pressure
superheated steam exhibits significant capacity
and conversion efficiency losses as a result of silica
contaminated steam latter tends to from insoluble
deposits on critical part of the turbine leading to
surface roughness which, in turn, is detrimental to
turbine efficiency. In order to assure optimum
turbine performance continuous monitoring of
silica in superheated steam, boiler water and
feedwater is of the utmost importance. The
polymetron silcostat has been designed specifically
to complete this task.
Analyzers: -

Lines Coming from Type of Analysis

Line 1 Make up Drum water Specific conductivity

pH, specific
Line 2 Conedensate pump conductivity, cation
discharge conductivity,
dissolved oxygen,
sodium.

Line 3 LP heater / inlet pH, specific

conductivit
y, dissolved
Oxygen.

Line 4 Feed water booster Dissolved

pump
Oxygen.

Line 5 Feed water pH, specific

Economizer conductivit
inlet y, cation
conductivity, silica,
Hydrazine.

Line 6 Boiler drum water pH, specific

conductivit
y, silica.

Line 7 Boiler saturated Specific conductivity,

Steam cation
conductivit
y.

Line 8 Main steam Specific conductivity,

cation
conductivit
y, silica.
Line 9 Hot well (2 off) Specific conductivity.

The sample analysis panel comprises the following

analyzers: -

No. of Analyzers
Analysis
1 Single channel silica
1 Two channel silica
2 Dissolved oxygen
1 Hydrazine
14 Conductivity
4 pH
1 Sodium

ATRS [Automatic Turbine Run Up System ]: -

Introduction-
All control function related to turbine are
realized by Microprocessor based PROCONTROL ATRS
System. This is based on user friendly programming
languageP10. The system is divided in three sub groups: -
1. SGC-Oil :- Oil pumps(AOP,EOP,JOP) interlocks,
automatic & protn. Operation are realized in this group.
2. SGC-Conden. & Evac. : - CEP’s & vacuum pump
operation.
3. SGC-Turbine :- For automatic synchronization of
machine to the grid. Procontrol requires serial data
exchange confined to the electronic room(panels),
process computer(monitoring) and control room.
HARDWARE
The data transmission is performed
with two level serial bus system-
• Local Bus: - Local bus interconnects all input,
output, and processing electronic modules, which is part
of station. Each local bus work independently from any
other local bus or Intra-Plant.
• Intra – Plant Bus: - This bus interconnects its related
local buses via coaxial cables. And through which
Monitoring computer and diagnostic station connected.
 The local bus can be grouped together in the same panel
or distributed in different panels. Each massage is
cyclically transmitted over the local as well as intra-
plant buses and transmission freq. Is selectable and can
be every 10 ms.
PROCONTROL has following basic type of electronic
modules: -
• Individual Control modules: - These implemented to
control, supervise, monitor, protect individual valves,
pumps, fans etc. Modules equipped with a
microprocessor, built-in l/o and dedicated control entity
to control element. A serial l/o interface to the local bus
to receive process signals required for interlaces &
permissive logoc. Hardwired interface is also provided
to control room. Modules are- AS45, AS46, AS47.
• Programmable Processor:- This modules used for
automation and superimposed on the individual control
modules and allows to build control, protection and
alarms. Module is-PR05.
• Input/Output modules:- Various modules for
input/output capabilities and connected to local bus.
These modules can handle single, double throw
contacts, thermocouple, RTD’s, milliamp signals etc. or
to provide milliamp, voltage, electronic contact output
signals.

LOGIC: -
TURBINE PROTACTION
SN SERVICE ALARM
TRIP
1 Lub oil Pr V. Low
2.1kg/cm2
(2 out of Pr. Swth. Oprt.)

2 Cond vacuum V. Low -0.8

-0.7kg/cm2
(2 out of 3 vac. Swth. Oprt.)

3 HPT Exhst Stm Tmp V. Hi 480

510
(2 out of 3 T/C Tmp. Rises)

4 Axial Shift V. Hi +/-

0.5mm. +/- 1.0mm
(2 out of 3 Senser optd.)
Protection ON:- 1) FIRE PROT.2 CH-1 (2) FIRE
PROT.2 CH-2
3)ANY JOP ON & SPEED<10 RPM
&SPEED RELEASE
& SO/H2 DP>1.2 BAR
EMER.OIL PUMP(EOP-DC)
Protection ON:- 1 SLC EOP-DC CMD-51
(i) SLC EOP-DC ON & EOP AC
FAIL & L.O.PR<2.1
(ii) SLC EOP-DC ON & EOP AC
OFF & EOP AC DIST. &
LUBE OIL PR<2.1
EMER. OIL PUMP(EOP-AC)

Protection ON:- 1)FIRE PROT.2 CH-1 (2)FIRE

PROT.2 CH-2(3)EOP AC
PROT. ON
(i) SLC EOPAC ON & LUB OIL
PR<2.1
(ii) EOP DC ON
JACKING OIL PUMP-2
(JOP-DC)
Per. ON:- JOP-1(AC) OFF

Auto ON:- 1.SLC JOP-2 CMD-51

(i)SLC JOP-2 ON & JOP PR.<100
&TUR
SPEED<510
(ii)SLC JOP-2 ON &JOP-1 OFF &
JOP-1 DIST.
(iii) SLC JOP-2 ON & JOP AC
FAIL & TUR SPEED<510

Prot. ON:- 1) FIRE PROT.2 CH-1 (2)FIRE

PROT. 2 CH-2
3) JOP-1 OFF & JOP AC FAIL &
TUR SPEED<510

Prot. ON:- 1)FIRE PROT.2 CH-1 (2)FIRE

PROT.2 CH-2
3) JOP-1 OFF & JOPAC FAIL &
TUR SPEED>15 & TUR
SPD<2800