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ROLE OF INSTRUMENTAION AND & CONTROL ENGINEERING IN THE INDUSTRIES

CERTIFICATE

All the information filled above is approved by the undersigned

Sr. Manager

INSTRUMENTATION & CONTROL

CONTENTS

S.NO TOPICS PAGE

a.

b.

c.

d.

e.

f.

g.

h.

i.

j.

BHEL-An Overview

BHEL-Contribution To Various Core Sectors

Objective of INSTRUMENTATION

Activites at INSTRUMENTATION Dept.

Site Offices Visited

MANOMETRIC Lab

PYROMETRIC Lab

Thermal Power Station

Turbine Supervisory Instrumentation System

Conclusion

PREFACE

This 4 week training program is a part of 4 year degree course. Practical, industrial training mainly aims at making an individual aware to the industrial environment and its working atmosphere which means that one gets to know the limitation, constraints and freedom under which an engineer works. one also gets an opportunity to see from close quarter the worker-many interaction and the methods of work carrying out in the industry. This training mainly involves industrial and complete knowledge calibration, testing, maintenance and

measurement and control.

ACKNOWLEDGEMENT

I am gracefull to training and placement officer ...........who guided and helped me to avail this wonderful opportunity to undergo training in an industry like BHARAT HEAVY ELECTRICALS LIMITED (BHEL) Haridwar .

I would also like to express my sincere gratitude to Mrs. S.R. Chaudhary, Sr. Manager, BHEL-Haridwar, who was my training coordinator and Mr R.P.Ram Sir, who was my training instructor. The information and guidance provided by them helped me to gain invaluable knowledge about working of the industry and the latest development in the field.

Last but not least I am obliged to all the other employees for their guidance and co-operation during the training period.

BHEL :AN OVERVIEW

Over the years, Bharat Heavy Electricals Limited has emerged as world class

Engineering and Industrial giant, the best of its kind in entire South East Asia.

Its business profile cuts across various sectors of Engineering/Power utilities

and Industry. The Company today enjoys national and international presence

featuring in the "Fortune International-500" and is ranked among the top 12

companies in the world, manufacturing power generation equipment. BHEL has

now 14 Manufacturing Divisions, 8 Service Centers and 4 Power Sectors

Regional Centers besides a large number of project sites spread over India and

abroad.

The Company is embarking upon an ambitious growth path through clear

vision, mission and committed values to sustain and augment its image as a

world class enterprise.

VISION

World class, innovative, competitive and profitable engineering enterprise

providing total business solutions.

MISSION

The leading Indian engineering enterprise providing quality products systems

and services in the fields of energy, transportation, infrastructure and other

potential areas.

VALUES

Meeting commitments made to external and internal customers.

Foster learning creativity and speed of response.

Respect for dignity and potential of individuals.

Loyalty and pride in the company.

Team playing.

Zeal to excel.

Integrity and fairness in all matters.

HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)

At Hardwar, against the picturesque background of Shivalik Hills, 2 important

manufacturing units of BHEL are located viz. Heavy Electrical Equipment Plant

(HEEP) & Central Foundry Forge Plant (CFFP). The hum of the construction

machinery woke up Shivalik Hills during early 60s and sowed the seeds of one

of the greatest symbol of Indo Soviet Collaboration – Heavy Electrical

Equipment Plant of BHEL. Following is the brief profile of Heavy Electrical

Equipment Plant:-

ESTABLISHMENT AND DEVELOPMENT STAGES:

Established in 1960s under the Indo-Soviet Agreements of 1959 and

1960 in the area of Scientific, Technical and Industrial Cooperation.

DPR – prepared in 1963-64, construction started from October '63.

Initial production of Electric started from January, 1967.

Major construction / erection / commissioning completed by 1971-72 as

per original DPR scope.

Stamping Unit added later during 1968 to 1972.

Annual Manufacturing capacity for thermal sets was expanded from

1500 M to 3500 MW under LSTG. Project during 1979-85 (Sets upto

500 MW,extensible to 1000/1300 MW unit sizes with marginal addition

in facilities with the collaboration of M/s KWU-Siemens, Germany.

Motor manufacturing technology updated with Siemens collaboration

during 1984 to 1987.

Facilities being modernized continually through Replacements /

Reconditioning-Retrofitting, Technological / operational balancing.

HEEP: FACILITIES AND INFRASTRUCTURE

Modernisation and regular Upgradation / up gradation of facilities and other

infrastructure is a continuous endeavor at HEEP, BHEL. After initial setting up

of the plant during the year 1964-72, in collaboration with the Soviet Union, the

plant facilities and infrastructures have since been continuously upgraded under

various investment projects vise, Stamping Unit Project, LSTG Project, Motor

Project, Governing Components Project, TG Facilities Modernisation, TG

Facilities Augmentation, Quality Facilities Augmentation, EDP projects, Gas

Turbine Project, Facilities have also been added and establishments have been

created for new projects in Defense and Aviation Project. Additionally, R &D

facilities have also been created under Generators Research Institute, Pollution

Control Research Institute, HTL modernization and other such schemes.

Today the Plant has unique manufacturing and testing facilities,

computerized numerically controlled machine-tools, Blade shop, heavy duty

lathes, milling machines, boring machines, machining centers and many more.

The Over Speed Vacuum Balancing Tunnel created for rotors up to 1300 MW

(32T, 6.9 M – dia bladed rotor, 6 rpm up to 4500 rpm) is one of the 8 of its kind

in the entire world.

The total spectrum of sophisticated, unique and other facilities at HEEP,

Hardwar are the state-of-the-art in manufacturing processes and can be utilized

for a variety of products' manufacture.

BHEL's CONTRIBUTION TO VARIOUS CORE SECTORS

POWER GENERATION

Power generation sector comprises thermal, gas, hydro and nuclear power

plant business as of 31.03.2001, BHEL supplied sets account for nearly 64737

MW or 65% of the total installed capacity of 99,146 MW in the country, as

against nil till 1969-70.

BHEL has proven turnkey capabilities for executing power projects from

concept to commissioning, it possesses the technology and capability to produce

thermal sets with super critical parameters up to 1000 MW unit rating and gas

turbine generator sets of up to 240 MW units rating. Co-generation and

combined-cycle plants have been introduced to achieve higher plant

efficiencies. to make efficient use of the high-ash-content coal available in

India, BHEL supplies circulating fluidized bed combustion boilers to both

thermal and combined cycle power plants.

The company manufactures 235 MW nuclear turbine generator sets and has

commenced production of 500 MW nuclear turbine generator sets.Custom made

hydro sets of Francis, Pelton and Kapian types for different head discharge

combination are also engineering and manufactured by BHEL.In all, orders for

more than 700 utility sets of thermal, hydro, gas and nuclear have been placed

on the Company as on date. The power plant equipment manufactured by

BHEL is based on contemporary technology comparable to the best in the world

and is also internationally competitive.

The Company has proven expertise in Plant Performance Improvement through

renovation modernisation and uprating of a variety of power plant equipment

besides specialised know how of residual life assessment, health diagnostics and

life extension of plants.

POWER TRANSMISSION & DISTRIBUTION (T & D)

BHEL offer wide ranging products and systems for T & D applications.

Products manufactured include power transformers, instrument transformers,

dry type transformers, series – and stunt reactor, capacitor tanks, vacuum – and

SF circuit breakers gas insulated switch gears and insulators.

A strong engineering base enables the Company to undertake turnkey

delivery of electric substances up to 400 kV level series compensation systems

(for increasing power transfer capacity of transmission lines and improving

system stability and voltage regulation), shunt compensation systems (for power

factor and voltage improvement) and HVDC systems (for economic transfer of

bulk power). BHEL has indigenously developed the state-of-the-art controlled

shunt reactor (for reactive power management on long transmission lines).

Presently a 400 kV Facts (Flexible AC Transmission System) project under

execution.

INDUSTRIES

BHEL is a major contributor of equipment and systems to industries,

cement, sugar, fertilizer, refinances, petrochemicals, paper, oil and gas,

metallurgical and other process industries. The range of system & equipment

supplied includes: captive power plants, co-generation plants DG power plants,

industrial steam turbines, industrial boilers and auxiliaries. Wate heat recovery

boilers, gas turbines, heat exchangers and pressure vessels, centrifugal

compressors, electrical machines, pumps, valves, seamless steel tubes,

electrostatic precipitators, fabric filters, reactors, fluidized bed combustion

boilers, chemical recovery boilers and process controls.

The Company is a major producer of large-size thruster devices. It also supplies

digital distributed control systems for process industries, and control &

instrumentation systems for power plant and industrial applications. BHEL is

the only company in India with the capability to make simulators for power

plants, defense and other applications.The Company has commenced

manufacture of large desalination plants to help augment the supply of drinking

water to people.

TRANSPORTATION

BHEL is involved in the development design, engineering, marketing,

production, installation, maintenance and after-sales service of Rolling Stock

and traction propulsion systems. In the area of rolling stock, BHEL

manufactures electric locomotives up to 5000 HP, diesel-electric locomotives

from 350 HP to 3100 HP, both for mainline and shunting duly applications.

BHEL is also producing rolling stock for special applications viz., overhead

equipment cars, Special well wagons, Rail-cum-road vehicle etc., Besides

traction propulsion systems for in-house use, BHEL manufactures traction

propulsion systems for other rolling stock producers of electric locomotives,

diesel-electric locomotives, electrical multiple units and metro cars. The electric

and diesel traction equipment on India Railways are largely powered by

electrical propulsion systems produced by BHEL. The company also undertakes

retooling and overhauling of rolling stock in the area of urban transportation

systems. BHEL is geared up to turnkey execution of electric trolley bus

systems, light rail systems etc. BHEL is also diversifying in the area of port

handing equipment and pipelines transportation system.

TELECOMMUNICATION

BHEL also caters to Telecommunication sector by way of small, medium and

large switching systems.

RENEWABLE ENERGY

Technologies that can be offered by BHEL for exploiting non-conventional

and renewable sources of energy include: wind electric generators, solar

photovoltaic systems, solar lanterns and battery-powered road vehicles. The

Company has taken up R&D efforts for development of multi-junction

amorphous silicon solar cells and fuel based systems.

INTERNATIONAL OPERATIONS

BHEL has, over the years, established its references in around 60 countries of

the world, ranging for the United States in the West to New Zealand in the Far

East. These references encompass almost the entire product range of BHEL,

covering turnkey power projects of thermal, hydro and gas-based types,

substation projects, rehabilitation projects, besides a wide variety of products,

like transformers, insulators, switchgears, heat exchangers, castings and

forgings, valves, well-head equipment, centrifugal compressors, photo-voltaic

equipment etc. Apart from over 1110MW of boiler capacity contributed in

Malaysia, and execution of four prestigious power projects in Oman, Some of

the other major successes achieved by the Company have been in Australia,

Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan,

Sri Lanka, Iraq etc.

The Company has been successful in meeting demanding customer's

requirements in terms of complexity of the works as well as technological,

quality and other requirements viz extended warrantees, associated O&M,

financing packages etc. BHEL has proved its capability to undertake projects on

fast-track basis. The company has been successful in meeting varying needs of

the industry, be it captive power plants, utility power generation or for the oil

sector requirements. Executing of Overseas projects has also provided BHEL

the experience of working with world renowned Consulting Organisations and

inspection Agencies.

In addition to demonstrated capability to undertake turnkey projects on its

own, BHEL possesses the requisite flexibility to interface and complement with

International companies for large projects by supplying complementary

equipment and meeting their production needs for intermediate as well as

finished products.

The success in the area of rehabilitation and life extension of power projects

has established BHEL as a comparable alternative to the original equipment

manufactures (OEMs) for such plants.

TECHNOLOGY UPGRADATION AND RESEARCH &

DEVELOPMENT

To remain competitive and meet customers' expectations, BHEL lays great

emphasis on the continuous upgradation of products and related technologies,

and development of new products. The Company has upgraded its products to

contemporary levels through continuous in house efforts as well as through

acquisition of new technologies from leading engineering organizations of the

world.

The Corporate R&D Division at Hyderabad, spread over a 140 acre complex,

leads BHEL's research efforts in a number of areas of importance to BHEL's

product range. Research and product development centers at each of the

manufacturing divisions play a complementary role.

BHEL's Investment in R&D is amongst the largest in the corporate sector in

India. Products developed in-house during the last five years contributed about

8.6% to the revenues in 2000-2001.

, 36 kV gas-insulated sub-stations, etc. The Company has also BHEL has

introduced, in the recent past, several state-of-the-art products developed in-

house: low-NQx oil / gas burners, circulating fluidized bed combustion boilers,

high-efficiency Pelton hydro turbines, petroleum depot automation systems

transferred a few technologies developed in-house to other Indian companies for

commercialisation.

Some of the on-going development & demonstration projects include: Smant

wall blowing system for cleaning boiler soot deposits, and micro-controller

based governor for diesel-electric locomotives. The company is also engaged in

research in futuristic areas, such as application of super conducting materials in

power generations and industry, and fuel cells for distributed, environment-

friendly power generation.

OBJECTIVES OF INSTRUMENTATION

To ensure timely Calibration of Process Instruments (Temperature,

Pressure and Flow measuring instruments) as per schedule and within 7

days of receipt of Instruments and monitor through QTM.

To streamline repair and recalibration of Temperature, Pressure and

Flow measuring instruments.

To Maintain Status of Calibration - 100%

To Enhance Quality and Efficiency of Response Time in Calibration.

To Increase Competency of Laboratory in Calibration.

SITE OFFICES

MANOMETERIC LAB PYROMETERIC LAB

Block-1 T G Test bed Site

Block-4 MICALASTIC Plant Site

Thermal Power Station Site

A. MANOMETERIC LAB: Caters to Calibration and Repairing needs of all the Pressure related Instruments of HEEP.

PRESSURE INSTRUMENTS:1. PRESSURE GAUGES:

BOURDON TUBE DIAPHRAGM TYPE

2. PRESSURE TRANSMITTER 3. PRESSURE SWITCH 4. U TUBE MANOMETER

B. PYROMETERIC LAB: Caters to Calibration and Repairing needs of all the Temperature related Instruments of HEEP.

TEMPERATURE INSTRUMENTS:1. RECORDERS 2. DIGITAL TEMPERATURE INDICATOR CONTROLLER 3. TRANSMITTERS 4. THERMOSTATS 5. DIAL TEMPERATURE INDICATOR

6. MERCURY IN GLASS THERMOMETER

7. RADIATION PYROMETER 8. THERMAL CHALK 9. SENSORS

RTDs - PRT-100,CRT . THERMOCOUPLEs - J,K,S,R,T Types .

C. Block-1 T G Test bed Site: This Site caters to:

Calibration and maintenance of all temperature, level, flow related instruments in Block-1.

Attend Breakdowns in its area. Provide support for TG and Exciter Testing .

D. Block-4 MICALASTIC Plant Site: This Site caters to:

Calibration and maintenance of all temperature, level, flow related instruments in Bl-4,Bl-2, Acetylene Plant, Compressor House, Oxygen Plant, CPL .

Attend Breakdowns in its area.

E. Thermal Power Station Site: This Site caters to:

Calibration and maintenance of all temperature, level, flow related instruments in Bl-5, Bl-6, Bl-8, TPS.

Attend Breakdowns in its area.

ACTIVITIES AT INSTRUMENTATION DEPT.

CALIBRATION MAINTENANCE T. G. TESTING SUPPORT OSBT MEASUREMENTS & CONTROLS INDENTING

CALIBRATION:

All the instruments of Pressure, Temperature and Flow from various Blocks of HEEP are Calibrated and Repaired in Instrumentation Labs. There are 3500 instruments located at different sites in Plant.

MAINTENANCE:

Problems regarding to various process instruments at different sites are attended by Instrumentation staff. Most of the complaints are cleared within 1 day. To reduce breakdown time at some critical sites there is duplication of measurements.

T G TESTING SUPPORT:

There are about 300 critical parameters related to Pressure, Temperature, Level and Flow to be observed and some of them controlled also during testing of TG.

OSBT MEASUREMENTS & CONTROLS:

There are about 100 critical parameters related to Pressure, Temperature, Level and Flow to be observed and some of them controlled also during testing and balancing of TG in OSBT.

INDENTING:

Specifications are made for Temperature, Pressure, Level and Flow instruments required for different applications in production Blocks and services areas by Instrumentation Section.

MANOMETRIC LAB

INSTRUMENTS AT MANOMETRIC LAB

The Instrumentation Section of Works Engineering and Services Department

deals with Testing, Calibration, Maintenance and Modernization of Pressure,

Temperature, Flow and Level Instruments.

PRESSURE INSTRUMENTS

1.PRESSURE GAUGES:

BOURDON TUBE:

The bourdon tube is the most frequently used pressure gauge because of its simplicity and rugged construction. A C-Type bourdon tube consist of long thin walled cylinder of non-circular cross section, sealed at one end, made from materials such as phosphorus bronze, steel and beryllium copper, and attached by a light line work to the mechanism which operates the pointer. The other end of the tube is fixed and open for the application of the pressure which is to be measured.

As the fluid under pressure enters the bourdon tube, it tries to change the section of tube from oval to circular, and this tends to straighten out the tube. The resulting movement of the free end of the tube causes the pointer to move over the scale. The tip of the bourdon tube is connected to a segmental lever through

an adjustable length link. The segment lever end on the segment side is provided with a rack which meshes to a suitable pinion mounted on a spindle. The segmental lever is suitably pivoted and the spindle holds the pointer.Bourdon tubes are made from number of materials, depending upon the fluid and the pressure for which they are used. Bourdon tubes are generally made in three shapes:

a. C-type

b. Helical type

c. Spiral type

DIAPHRAGM TYPE:

Diaphragms are widely used for pressure and draft measurement, particularly in very low ranges. They can detect a pressure differential even in the range of 0 to 4mm.

The diaphragms can be in the form of flat, corrugated or dished plates and the choice depends on the strength and amount of deflection desired. In high

precision instruments the diaphragms are generally used in pairs, back-to-back, to form an elastic capsule.With suitable modification, diaphragm can be made to cause changes in electric circuits, thus converting pressure movements to electrical signals which can be transmitted to an indicating or a recording system.

2.PRESSURE SWITCH:

A pressure switch turns an electric circuit ‘ON’ or ‘OFF’ at a preset pressure. This pressure is called the set point of the switch. The pressure switch is usually a microswitch or a mercury switch. A bourdon tube, a diaphragm or a bellows can be used to actuate the switch.

The pressure is fed to the inside of the bellows which carries a contact plate. When the pressure reaches a sufficient value (or preset) value, the contact plate touches contact points thus closing an electric circuit to an alarm or motor control gear. The contacts in a pressure switch may be normally closed when the pressure is below set point. For example, the contacts in a normally open switch remains open until the pressure rises above the set point. Then the sensing element makes the contact snap to the closed position. The contacts open again when the pressure falls below the set point. The contacts in a normally closed switch remain closed until the pressure rises above the set point. Then the contacts snap open and remain open until the pressure drops below the set point again. Most switches contain two sets of contacts, one

normally open and the other normally closed.A pressure switch has a “deadband”, i.e. the pressure must fall below the set point before the switch resets to its normal position. The amount of deadband is the difference in the pressure between the set point and the reset point.

3. U TUBE MANOMETER:

The U-tube is the simplest form of manometer. By suitable choice of liquids, a wide range of pressure can be recorded.It consist of a transparent tube constructed in a firm of elongated U and is partially filled with a liquid, most commonly water or mercury. Water and mercury are used because their specific weights for various temperatures are known exactly and they do not stick to the tube. One end of the U tube is connected to one pressure tap and the other end is

connected to the other pressure tap, or it may be left open to the atmosphere. When there is a pressure difference between the two ends of the tube, the liquid level goes down on one side of the tube and up on the other side. The difference in liquid levels from one side to the other indicates the difference in pressure.

When manometer is used to measure low pressures then water is used as the liquid, and when it is used to measure high pressures then mercury is used as the liquid. Mercury is almost 14 times as heavy as water. Therefore, the difference in levels of mercury-filled manometer is about 1/14 of what it would be if water were in the tube.

The pressure difference in a vertical U-Tube manometer can be expressed as

pd = γ h (1)

where

pd = pressure

γ = specific weight of the fluid in the tube (kN/m3, lb/ft3 )

h = liquid height (m, ft)

The specific weight of water, which is the most commonly used fluid in u-tube manometers, is 9.8 kN/m3 or 62.4 lb/ft3

4.PRESSURE TRANSMITTERS:

The DPharp EJX series of pressure transmitters /differential pressure transmitters are the latest addition to the DPharp family's EJA series. DPharp EJX pressure and differential pressure transmitters employ a next-generation multi-sensing technology that provides virtually the highest level of performance and precision in the market

PYROMETERIC LAB

INSTRUMENTS AT PYROMETRIC LAB

Caters to Calibration and Repairing needs of all the Temperature related Instruments of HEEP.

TYPES OF TEMPERATURE INSTRUMENTS

1. THERMOCOUPLE

BASIC THERMOCOUPLE

CERAMIC TWIN BORE INSULATED THERMOCOUPLE

b

GENERAL PURPOSE THERMOCOUPLE

HAND HELD THERMOCOUPLE PROBE

2.RESISTANCE TEMPRATURE DETECTORS (RTD)

CAPSULE DESIGN PLATINUM RTD

BIRD CAGE HIGH TEMPERATURE RTD

INDUSTRIAL WIRE WOUND RTD

2. RECORDERS:

A recorder records electrical and non-electrical quantities as a function of time. Electrical quantities, like currents and voltages, can be recorded directly, while non-electrical quantities, such as pressures, flows, levels, etc. are recorded indirectly by first converting them into equivalent currents or voltages with the help of sensors or transducers

.Basically, there are two types of recording system:

Analog recorders Digital recorders

There are three types of analog recorders:

Graphic recorders Magnetic tape recorders Oscillographic recorders

Digital recorders fall into two basic groups:

Return-to-zero(RZ) Non-return-to-zero(NRZ)

3. GRAPHIC RECORDERS:

Graphic recorders are devices which display and store a pen-and-ink record of the history of some physical event. The event may be a varying voltage or current obtained from an electric circuit under observation or perhaps a varying pressure which actuates a diaphragm and linkage to move a stylus in relation to a chart.

A graphic recorder consists of:

a. chart for displaying and storing the recorded information.

b. Stylus moving in a proper relationship to the paper.

Suitable inter-connection means to couple the stylus to the information source.

4. RADIATION PYROMETERS:

Operation of radiation pyrometers is based upon the measurement of radiant energy emitted by the hot body. It consists of a lens to focus radiated energy from the body, whose temperature is required, on to a detector or a receiving element. This receiving may have a variety of forms such as resistance thermometer, or a thermocouple, or thermopile. A thermopile consists of several thermocouples connected in series. A temperature indicator, recorder, or controller is attached with the receiving element to indicate the temperature.When the total energy radiated by a hot body, whose temperature is to be measured, enters the pyrometer it is focused by the lens on to the detector. The detector is a thermopile whose measuring junctions are attached to a blackened disk. The disk absorbs energy when the pyrometer is focused on a hot body, and its temperature rises. The reference junction of the thermopile is attached to the pyrometer case. The difference in temperature between the measuring junction attached to the disk and the reference junction attached to the case generates a voltage that is directly related to the temperature of the blackened disk, which is indicated by the recording instrument.

Applications:

a. They are used for the temperature above the practical operating range of thermocouples.

b. They can be used in the environments which contaminate or limit the life of thermocouples.

c. They are used for moving targets.

TURBINE SUPERVISORY INSTRUMENTATION

EXPANSION , VIBRATION , AND VALVE POSITION MEASUREMENT:

In the operation of large steam turbine certain vital parameters are required to be continuously supervise and monitored in oder to provide information related to the operational conditions of the turbine during various stages operation ike start up ,loading ,load change ,shut down .

The special measurement system include all necessary sensors mounted on turbine with flexible leads for processing the sensor signal along with power supply monitoring ,signal level monitoring , signal level moniters ,test circuit etc ,in a cabinet to generate information about the following parameters :

a. Absolute bearing vibration s x and y direction .

b. Absolute shaft vibration X and Y direction .

c. Axial shaft position of the rotor.

d. Shaft expansion .

e. Valve position .

Other important parameters like speed will be monitored by electrohydraulic governing system and binary signal conditioning cabinets , and displayed in the unit control room .

ABSOLUTE BEARING VIBRATION

The sismic mass type pickup is mounted on the bearing pedestal .the bearing vibration are transmitted directly to the seismic device.

The device operates on the plunger coil principle .a coil is suspended in the air gap in a resilient way by a spring .The magnetic flux in the air gap is constant the permanent magnet is frimly connected to the housing and the magnetic return path .Above the inherent frequency of the spring /mass system .The plunger coil is steady in its space due to mass inertia .thus a fix point is created and the vibrations can be referred to this point .The relative motion between the coil and the magnet generates a voltage which is proportional to the rate of vibration

The measurement system is designed to operate satisfactorily over a frequency range of 16HZ to 200HZ and measures the amplitude of the output voltage of the sensor is amplified in a differential amplifier ,which suppress any interference voltage picked up by the cable .Then the signal is integrated in an active integrated circuit to form signal proportional to vibrational displacement it is then rectified and then displayed

The functioning of the amplifier can be cheaked with the help of a standard oscillator built in the system .Faliur of the sensor and the field cable will be annunciated .Similarly the supply voltage is also monitored

ABSOLUTE SHAFT VIBRATION :

Measurement is done by measuring the relative shaft vibration with respect to the bearing pedestal and adding the absolute bearing vibration to it

The measurement of the relative shaft vibration is done in a contactless manner according to the eddy current method .An oscillating circuit consist of the disk –shaped coil of the sensor and the cable capacitance of the feed line receiving a high frequency a.c current from the adaptor mounted on the bearing cover ,corresponding to the resonant frequency of the oscillating circuit .The

electromagnetic alternating field generated in the process induces eddy current on the shaft opposite to the coil .The smaller the distance beteen the coil and the shaft larger in the current .The eddy current feed back to the current is felt as an increasing effective load ,so that the a.c voltage at the coil is proportional to the distance between the sensor and the shaft

AXIL SHAFT POSITION OF THE ROTOR:

The measurement yields information on the position of the shaft in the thrust bearing and on the wear of the bearing .It is imperative to continuously moniter the position of the shaft as axil shift beyond the permissible limits would lead a mechanical interference and mechanical rubbing

The measuring principle is based on the fact that the impedence of the coil with the iron core depend upon the size of the air gap in a magnetic circuit . There are two such coils mounted on either side of the measuring disc ,and connected to form a measuring bridge .A high frequency voltage from an oscillator is fed to the bridge ,the output of which changes proportionally to the change in the air gap .The bridge output voltage is rectified by phase selection and amplified

The shaft position measurement is carried out with the three proximity type sensors .The three measured signals are used in a 2 out of three configuration featuring analog comparison with cyclic test

The measurement range is - 1.5 to+1.5 mm

SHAFT EXPANSION

SHAFT expansion is done in the same way as described earlier for axial shaft position measurement .The difference lies in the size of the measuring device

and the sensor arrangements .The measuring disc is in the form of a double cone to produce less change in the air gap due to large change in the expansion

As a bridge output for a large air gap change become non linear a linearising network is also used in the electronic processing

The range of measurement is -10 to +38mm

VALVE POSITION

The measurement is carried out for both the HP and LP control valves with the help of displacement sensor .The displacement sensor is connected to the valve rod via a connecting device and a rope .The other end of the rope is connected to a rotable measuring device which forms the magnetic return path for the sensor coils .The rotating measuring device rotates eccentric to the sensor coil which creates different air gaps and thus different inductance thus the air gap between the measuring device and the coils depend upon the angle of rotation .The displacement sensor is arranged in such a manner that the rope is extended in the zero position ,i.e with the valve closed the output is zero.

THERMAL POWER STATION (TPS)

BHEL haridwar had its own power plant to generate electricity .It was set up in 1968 with Russian collaboration and started generation in 1970.it had the generating capacity of 12MW.

At present the thermal power plant is no more in use and in its place diesel engine has been put up with the generating capacity of nearly 6MW.

BOILER

The TPS has three Russian boilers of capacity 35 tons/hr/boiler at a pressure of 40 kg .height of the boiler is 16 mtrs

THESE BOILERS CAN BE CLASSIFIED AS :

a. Fire tube Boiler :In this, fire is contained in the tubes of the boiler .

b. Water tube Boiler :In this water is contained in the tubes of the boiler and the chamber is full of fire . it is also called vertical water tube pulverized coal fire boiler .powdered coal is obtained from hammer mill .presently this type of boiler is in use .hammer is of manganese steel .there are seventy two hammers in a mill with a weight of 10 kg each

.

BASIC CONSTITUENTS OF THE BOILER ARE AS FOLLOWS

a. Pipes:Boiler is surrounded by water tubes of dimensions 60*3.5mm(dia*thickness).These pipes are of alloy steel .These pipes in boilers are known as water walls having 5-6mm gap .Both ends of these pipes are fitted to a header (a thick pipe ).There are about 240 tubes in whole .

b. Fuel :RFO oil is used in the boiler for burning .It is the lowest quality oil obtained as the petroleum by-product .It also requires pulverized coal ,fire and air as fuel .Oil is introduced through the burner .

c. Super heater :It produces the super heated steam at a temperature of 440 deg centigrade .The maximum steam pressure in the boiler is 40 atm .

d. boiler drum :It is made up of alloy steel .Its basic functions are :

i. filter

ii. To supply water to boiler tubes

iii. To collect steam from boilers.

e. Seperator :Steam strikes with the separator and the water particles drop down .

f. Economiser :The boiler consist of two economisers called as lower economiser maintained at 243 deg. Centigrade and upper economiser maintained at 105 deg centigrade .These are coil tubes through which the flue gases pass

g. Air pree heater :it is a heat exchanger in which some heat is extracted from the gases and is used to heat the incoming air for combustion .These allows the saving of a lot of fuel .If increment in temperature of air is 20 deg the boiler efficiency increases about 1 %.

h. Forced draft fan :It sucks the atmospheric air to produce vacuum in the boiler .

i. Induced draft fan :It is connected to the electrostatic precipitator to throw unwanted coal gas to the chimney .

j. Electrostatic Precipitator: It contains large size electrodes ,which continuously vibrate by passing D.C. through it .Its function is to filter the coal particles to fall down and only allow gases to pass through the chimney.

k. Chimne y :Total height of the chimney is 80 mtrs.Base upto 20 mtrs as of cement .Remaining 60 mtrs is of steel .At the top the dia. is 2 mtrs .It is connected to the I.D. fan .

2.CONDENSER:Condenser consist of two parts with 1800 water tubes in each parts . Therefore the total water tubes in the condenser are 3600. The tubes RE Made of brass and have dimensions of 18*1(dia*thickness) .When hardness comes in water ,then we eject sofium phosphate.The steam extracted from theturbines fallsinto the converted into water forming condensate water .this condensate water after passing through L.P. heaters ,de-air heater and by using feed pumps those back to the boiler .

3. TURBINE:Turbine is placed in the turbine hall .impulse turbines are used at TPS having 28 stationary and 28 rotatory blades .it is a machine in which a shaft is rotated by the impact of steam of working substance .It converts potential energy of the working substance into mechanical energy.

Working of steam turbines depends upon the dynamic of the steam .the steam is caused to fall with pressure in the nozzle ;due to fall in pressure a whole amount of heat is converted into mechanical energy

4. GENERATOR:Presently BHEL is using a Russian generator having

Capacity : 12MW

Apparent : 15MVA

P.F : 0.8 Lag

Rated voltage : 11KV

Rated current : 788A

Speed : 3000 rpm

CONCLUSIONThe industrial practical training is introduced by the university with the idea of familiarizing the students with the working condition in a professional firm as well as to apply their theoretical knowledge acquired in the institute in the practical. It has been seen that though the student poses thorough theoretical knowledge he/she falters when it comes to applying that knowledge to some practical use. So, it becomes very important for the students to know practically the working of some of the theoretical knowledge that he/she has gained. As we are all aware of the fact that though the college may have all the facilities available, working in it keeping in view broad prospective become quite difficult. It is because, a company will design and develop any project keeping in view its cost and its compatibility with the surrounding and still not compromise on the quality. The basic difference between an institution and industry lies in the fact that people in the industry are more professional in their attitude. The outlook of the person doing the job in the industry varies vastly that of today. The simple great thing to watch and enjoy in an industry is the teamwork involved. All the work given to any department is divided into group tasks, in which each task is assigned to a certain number of people in the group. This is one of the areas where institution lacks unknowingly. As even the institution stresses the point of teamwork in any field, the professional attitude misses in it which a student can try and gain during his\her training duration in the industry. Earlier, the student makes a big leap when he\she used to jump from an institution to an industry. Now, with the help this training a student feels that the earlier big jump is know a small step. This is by no means is small matter but very important as whole.

BHEL, Haridwar is no different when it comes to professionalism. Ample example of team work and dedication are found. The working atmosphere which is so important for an industry it seems to be believed here.