training report for bhel[1]

8/14/2019 Training Report for Bhel[1]

1/20

Training Report

On

TURBINE CONTROL & INSTRUMENTATON

Submitted in the partial fulfillment of the requirements

For the 8thsemester curriculum of degree of

Bachelor of Technology

in

Electronics and Instrumentation Engineering

of

BABU BANARASI DAS INSTITUTE OF TE!NO"O#$

#!A%IABAD

Under the guidance of& - Su'mitted By&(

Mr. Rampher Ram Yogesh Kumar


2/20

ACKNOWLEDGEMENT

I express m appreciation for all those !ith !hom I !or"ed and interacted in #.$.%.&I express m appreciation for all those !ith !hom I !or"ed and interacted in #.$.%.&

and than" them for their help and cooperation.and than" them for their help and cooperation.

. I am deepl indebted to. I am deepl indebted to Mr. Rampher Ram for his meticulous guidancefor his meticulous guidance

and help in completing m training and understanding the compan cultureand help in completing m training and understanding the compan culture

..


3/20

B!E"(AN O)ER)IE*

INTRODUTION&

In '()* India too" a ma+or step to!ards the establishment of its hea, engineering

industr !hen #harat $ea, %lectricals &imited the first hea, electrical

manufacturing unit of the countr !as set up at #hopal. It progressed rapidl and

three more factories !ent into production in '()* .he aim of establishment #$%&

!as to meet the gro!ing po!er requirement of the countr.

#$%& has supplied (/0 of the po!er generating equipment that !as commissioned

in India during '(/(-81. #$%& has supplied generating equipment to ,arious utilities

capable of generating o,er '8111M2 po!er.

#$%& is one of the largest po!er plant equipment manufacturing firms in India and it

ran"s among the top ten manufacturers globall. #$%& has co,ered up man po!er

stations o,er 31 countries !orld!ide.

#$%& has it head quarters at 4e! 5elhi. Its operations are spread o,er ''

manufacturing plants and number of engineering and ser,ice di,isions located across

the countr. he ser,ice di,ision includes a net!or" of regional offices throughout

India.

#$%&6S 74IS I4 I45I9-

S+No+ ,"AE UNITS -,"ANTS.

'. $R52R :

:. #$;?5IS$


4/20

B!E"(A BRIEF !ISTOR$

he firstplant of !hat is toda "no!n as #$%& !as established nearl 31 ears ago

at #$;


5/20

Transportation

high percentage of trains operated b Indian Rail!as are equipped !ith

#$%&6s traction and traction control equipment including the metro at Ealcutta. he

compan supplies broad gauge electrical locomoti,es to Indian Rail!as and diesel

shunting locomoti,es to ,arious industries.)111*111 hp E5E locomoti,esde,eloped and manufactured b #$%& ha,e been leased to Indian Rail!as. #atter

po!ered road ,ehicles are also manufactured b the compan.

International Operations

#$%&6s products ser,ices and pro+ects ha,e been exported to o,er )1

countries ranging from 7nited States in the !est to 4e! Jealand in far %ast. he

cumulati,e capacit of po!er generating equipment supplied b #$%& outside India

is o,er =111M2. he compan6s o,erseas presence includes pro+ects in ,arious

countries. fe! notable ones are 9 ')1 M2 GIS;IH gas turbine to ?erman utilit

boilers and open ccle gas turbine plants to Malasia ripoli-!est po!er station in&iba executed on turn"e basis thermal po!er plant equipment to Malta and

Eprus $dro generators to ne! Jealand and hdro po!er plant equipment to

hailand. #$%& has recentl executed ma+or gas-based po!er pro+ects in Saudi

rabia and ;man a #oiler contract in %gpt and se,eral ransformer contracts in

Malasia and ?reece.

M47FE7I4? 74IS A


6/20

urbines A generators

Steam generators

$eat exchangers

8+ D# ,O*ER ,"ANTS& -9!ANSI.

$S5 natural gas biogas based diesel po!er plants etc. 7nit rating :1 M2 A

,oltage up to '' K for emergenc pac"ing as !ell base operations on

turn"e

:+ INDUSTRIA" SETS -!$DERABAD.

Industrial turbo sets of ratings from '.) to ':1 M2.

?as turbines load matching generators ranging from = to :)) M2 GIS;H

rating Industrial steam turbines A gas turbines for dri,e applications A cogeneration

applications.

/.,O*ER STATION E"ETRONIS E6UI,1ENTS& -BAN#A"ORE.

Microprocessor based distributed digital control sstems

5ata acquisition sstems

Man machine interface

Substation control !ith SE5

Static excitation equipment or automatic ,oltage regulator

%lectro hdraulic go,ernor control

Furnace safeguard super,isor sstems8.S*IT! #EAR& -B!O,A".

S!itchgear of the ,arious tpes for indoor and applications and ,oltage ratings

up to 3 K

Minimum ;il Eircuit #rea"er G ** K - '=: K H

SF* Eircuit #rea"er G '=: K 311 K H

acuum Eircuit #rea"er G =.= K == K

?as Insulated S!itchgear G =* K H

(.TRANSFOR1ER& -B!O,A".


7/20

5isc or suspension insulators for E or 5E applications ranging from 3) to

=11K electromechanical strength for clean and polluted atmosphere.


8/20

TRATION ONTRO" #EAR&

Eontrol gear equipment for rail!as and other traction applications

Eontrol and rela panels

Eontrol panels for ,oltages up to 311 K and control des"s for

generating stations and %$ substation

Eontrol and rela boards

urbine gauge boards for thermal gas hdro and nuclear sets

urbine electrical control cubicles

ransformer tap-changer panels

05+ SI"ION RETIFIERS& -B!O,A".

Silicon po!er rectifiers !ith matching transformers for industrial applications.

luminum or Eopper Jinc smelting for electrolsis in chemical industr and

E A 5E traction applications.

08+ T!$RISTOR E6UI,1ENT& - B!O,A" .

hrister Eon,erter %quipment

hrister In,erter %quipment

Static E ,ariable speed dri,e sstems

hrister ,alues for $5E transmission up to )11 K

0:+ ,O*ER DE)IES & - B!O,A" .

$igh po!er capacit silicon diodes and thristor de,ices and solar

photo,oltaic cells.

'/.TRANS,ORTATION E6UI,1ENT& -TIRU!$.

E electric locomoti,e

E 5E dual ,oltage electric locomoti,e

5iesel electric shunting locomoti,e

5iesel hdraulic shunting locomoti,e

;$% Recording cum test car

%lectric traction equipment G for diesel or electric locos electric multiple units

diesel multiple units and urban transportation sstems H

raction motors

ransformers smoothing reactors

raction generators or lternators

Rectifiers

#ogies

acuum circuit brea"ers

uxiliar machines

Microprocessor based electronic control equipment


9/20

Static In,ertors for auxiliar suppl

&oco control resistances i.e. field ele,ators dnamic bra"ing resistances and

inducti,e shunts.

raction Eontrol ?ear.

0


10/20

#$%& $RI52R

An O?er?ie/&

t the foothills of the ma+estic $imalaas A on the ban"s of a hol ?anges in Ranipurnear $R52R is located !ea?y Electricals E@uipment ,lant ofBharat Heavy

electrical limited?

#$%& !holl o!ned b the go,ernment of India is an integrated engineering

complex consisting of se,eral plants in India !here about /1111 !or"ers are bus in

design A manufacturing of a !ide range of hea, electrical equipment.

t present /10 of the countr6s electrical energ is generated b the sets

manufacturing b #$%& $ard!ar.

,RODUTS OF B!E" !ARID*AR&(

0+ !EE,S ,RODUT A,AIT$ RATIN#S

,RODUT A,AIT$ RATIN#

'. hermal setnuclear set :'1 M2-**1 M2

:. ?enerator different po!er stations acc. to requirement

=. ?as urbine *1 M2- :11 M2

3. $eat %xchangersEondenser 7p to 811 M2

3+ FF,s ,RODUT A,AIT$ RATIN#S&

,RODUT A,AIT$ RATIN#

aH Steam steel castings li"e steam *111 ones

Ehest turbine clinders stra rings

Runner blades etc.

bH Special steel forgings li"e steam turbine =:)1 ones

Rotors rotor discs hdro turbine shaft.L

B"OCS IN !EE,&

#&;EK-' urbo ?enerators E Machines


11/20

#&;EK-: Fabrication GSteam $dro A gas urbineH

#&;EK-= ?as A Steam urbine

#&;EK-3 EIM GEoil A Insulation ManufacturingH A Gpparatus control

gearH E?

#&;EK-) $eat exchangers Forging and Fabrication

#&;EK-* Stamping

#&;EK-/ 2ooden


12/20

My training is in Design Engineering wing - CONTROL &

INSTRUMENTATION ENGG. (C.I.E.) and ere I a! w"r#ing "n

T$r%ine C"ntr" & Instr$!entati"n.

TURBINE CONTROL &INSTRUMENTATON

INTRODUCTION:-

A successful start(up of the T#(set normally re@uires ac@uisition7 analysis and

collation of a /ide ?ariety of information pertaining to ?arious parameters lie

,ress7 Temp+7 and )acuum+ Speed etc+

Difficult tas for the operator to handle and collate so many 'its of informations/iftly correctly along /ith status of auiliary e@uipments

A 1icroprocessor 'ased ATRS ( Automatic Tur'ine Run Up system performs

this tas accurately and at an appropriate time+

CONCEPT:- A programma'le Automatic Tur'ine Run(up System -ATRS. is 'ased on the

Functional #roup ontrolG philosophy

The control area is di?ided into clearly defined functional areas called

Functional #roupsG

Each Functional #roup is organiHed arranged in S#7 S" and Dri?e

Interface Function


13/20

TASCS ,ERFOR1ED&( S/ift7 accurate and optimum startup - including synchroniHation and loudening.

of tur'ine

1aintaining oil supply

Building up and maintenance of ?acuum+

FEATURES &

Based on functional group control philosophy7 each functional su'(group

control7 su'(loop control7 and control interface operation along /ith status

displays in o/ns+ Operating modes a?aila'le&

( 1anual mode -operator guide.

( Automatic mode

( Step 'y step mode+


14/20

AD)ANTA#ES OF ATRS&(

Eliminates human error

,ro?ides maimum protection against malfunctions

Operators tas less arduous

Ena'les safe7 smooth7 stress consist ant and optimum /arm(up7 rolling and

synchroniHation of tur'ine in least possi'le time+

Increases plant a?aila'ility

Reduces starting time /ithout impairing life

1eets emergencies automatically

All plant operating conditions catered to 'y criteria dependant programming

Increased operating flei'ility7 safety and relia'ility+

SUB #ROU, ONTRO" - S#.&

S# eecutes commands to 'ring the e@uipment upto a particular defined

status+

The commands are eecuted in a predefined se@uence in the form of steps+

Desired num'er of criteria acts as preconditions 'efore the S# can tae off or

eecute its defined se@uence+


15/20

The functional group continues to function automatically all the time

demanding ena'ling criteria 'ased on the process re@uirements and from other

F#s7 if re@uired+

In case the desired criteria are not a?aila'le7 the system /ould automatically act

in such a manner as to ensure the safety of the main e@uipment+

The se@uence is programmed in the processor+ The process signals are ac@uired

through the input modules and are a?aila'le on the 'us+

WAITING AND MONITORING TIME FOR STEPS:-

*aiting Time& (It implies that the su'se@uent step /ill not 'e eecuted unless the specified time elapses+

If no /aiting time is specified7 the net step gets eecuted as soon as the ena'ling

criteria are fulfilled+

1onitoring Time&( It is the time re@uired for eecuting the command of any step as /ell as the timere@uired for appearance of criteria for the net step+ Under healthy conditions it should

happen /ithin the specified time7 other/ise an alarm is initiated+ *hene?er there is

uncertainty regarding the time re@uired for completing a particular tas7 such as

/arming(up7 pulling ?acuum etc+7 the monitoring time is 'loced+

,RO#RA1 STE, OF A SUB#ROU, ONTRO"&(

OUT,UTS AND A 1ONITORIN# *AITIN# TI1E +

*IT! ADDITIONA" ,RO#RA1 "OO, ONTRO" AND A B$,ASS+RITERIA FOR STE, 0&(

Step 3 - start up program. /ith 3 step criteria7 3 command *aiting or mo time can 'e programmed for ;+0 sec to >>> min+


16/20

Nos+ 0(5> used for start(up7 80 to >> for shutdo/n program+

*AITIN# AND 1ONITORIN# TI1E FOR STE,S&

ATRS can 'e s/itched on at any stage after completing certain tass manually7 if

so desired+ In such cases7 the S# program @uicly scans through the steps

and starts eecuting from the stage up to /hich the tass ha?e 'een completed

manually+ This is achie?ed 'y incorporating suita'le o?erflo/ 2'ypass conditionsin the logic+

ATRS CONTROLS:-

0+ ATRS is organiHed in the follo/ing three Su'(#roups& Oil supply system

E?acuation system

Tur'ine system

3+ S# issues commands either to the S" or directly to the dri?e through the ontrol

Interface+

4+ Each of these S#s has its su'ordinate S"s and

Dri?e ontrol 1acros+ These S#s in conJunction /ith the tur'ine go?erning system7

TSE and the auto(

SynchroniHer accomplishes the function of start(up of the T# set+

SUB("OO, ONTRO" -S". & A S"7 /hen s/itched on7 actuates the e@uipment and 'rings it to the desired

status as demanded 'y the process and there is no se@uence logic in?ol?ed in it+

S" is lie a /atch(dog performing an assigned duty+ All mechanical e@uipment /hich need to 'e s/itched on2off 'ased on process

consideration are hooed(up in ?arious S"s+ Stand'y e@uipment is also

interloced in S"s+

S" can 'e s/itched on either manually or through S# and issues commands

to the dri?e control le?el+

S" logic is also realiHed in the processor module+

(DRIVE CONTROL INTERFACE)

DRI)E ONTRO" 1AROs&-Soft/are realiHation.Basically three types of Dri?e ontrol 1acros&(

0 a. "TUD,B -for Unidirectional "T dri?es /ith ,ush'utton Interface.

'. "TUD -for Unidirectional "T dri?es /ithout ,ush'utton Interface.

3 a. BD,B -for Bidirectional dri?es /ith ,ush'utton Interface.

'. BD -for Bidirectional dri?es /ithout ,ush'utton Interface.

4 a. SO),B -for solenoid dri?es /ith ,ush'utton Interface.

'. SO) -for solenoid dri?es /ithout ,ush'utton Interface


17/20

DRI)E ONTRO" 1AROs& -Soft/are realiHation. The dri?e control macro functions -custom 'locs in maDNA terminology.

"TUD,B "TUD are used to control unidirectional dri?es such as pumps7 fans7

motors etc+7 Bi(directional dri?es -BD,B2BD. such as )al?es7 Dampers etc

The ,ush'utton commands "ED indications eclusi?ely

for "TUD,B2BD,B2SO),B are for interfacing /ith control des and not a?aila'le in

"TUD functional 'loc+Dri?e commands can 'e issued from&

( ,ush'utton panel in the control des

-only for "TUD,B2BD,B2SO),B.

( !1I 2 11I operator station

( Automatic higher le?el system

( ,rotection signals+

,ush'utton commands ON2OFF -O,EN2"OSE. are effecti?e only /hen pressed along

/ith ,ush'utton release+ ,ush'utton commands and auto commands are processed

along /ith the respecti?e release logic input signals+ ,rotection command inputs do notneed any release input+

No separate manual release re@uired for !1I commands+

The commands ON2O,EN or OFF2"OSE are a?aila'le for a pulse duration of 0;

seconds after initiation7 after /hich time it is /ithdra/n+ !o/e?er7 if the dri?e status

output in the desired -commanded. direction is a?aila'le /ithin this time7 the command

output is /ithdra/n+

-For SO) 2 unidirectional 2 'i(directional dri?es.


18/20

ATRS STRUCTURAL SYSTEM:

ATRS IS OR#ANISED IN T!REE S#s &

0+ S#(TURBINE S$STE1&SGC Turbine !"# $ire!"%& 'n "e '%%'*in+ #"e,#:

Su'(loop ontrol -S". Drains+

*arm up ontroller+

Starting De?ice of tur'ine go?erning system+

Speed "oad Set point de?ices of Tur'ine

#o?erning system+ Auto(synchroniHer+

3+ S#(OI" SU,,"$ S$STE1&

SGC 'i% #u%& $ire!"%& !"# 'n "e '%%'*in+ #"e,:

Su'(loop control -S". turning gear+

S" auiliary oil pumps 0+

S" auiliary oil pumps 3+ S" emergency oil pump+


19/20

S" Jacing oil pumps+

4+S#(condensate e?acuation system&

S#( ondensate E?acuation directly acts on the follo/ing systems&

Su'(loop ontrol -S". condensate etraction pumps+

Starting eJector7 if pro?ided+

1ain eJectors 2 )acuum pumps -as applica'le.+

)acuum 'reaer+


20/20

AD)ANTA#ES OF AUTO1ATION&( Operating personnel freed from routine tass+

Incorrect inter?entions in the process a?oided+

Stress on e@uipment reduced+

,lant operations geared for maimum efficiency+

Incipient faults recogniHed @uicly+

On fault occurrence7 immediate and

"ogical inter?ention possi'le

Name of guide&( 1r+ Rampher Ram+

Signature of guide&(

Remars 'y proJect e?aluating concerned+ &(

training report for bhel[1]

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