RAYALASEEMA THERMAL POWER PROJECT: STAGE-I

V.V.REDDY NAGAR.

PLANT PROFILE
 Rayalaseemea Thermal Power Project is
one of the major power generating facility in
ANDHRA PRADESH to meet the growing demand
of power in the southern part of the state.

This project envisaged the installation of 2 X 210

MW of Thermal Generation Units under Stage -1.
 The Rayalaseema Thermal Power Plant is located at
Kalamalla that is 12km from Proddatur. This is popularly
known as “THERMAL”. RTPP is spread in a wide area of
about 2800 acres. It is easily approachable by both rail and
road. The National Highway 7 runs at 8 km from power
station. The nearest railway station is Muddanur.

The project envisages the initialization of two thermal

generating units each capacity 210MW
PRINCIPLE OF GENERATION:

A Steam Power Plant converts Chemical

energy of fossil fuel into Thermal energy to Kinetic
energy to Mechanical energy and then into
Electrical energy. Raising the temperature and
pressure of steam in Boiler and then expanding it in
the Turbine to achieve this.
STRUCTURE OF GENERATOR:

The 210MW turbo generator having cylindrical rotor

uses direct Hydrogen cooling for the rotor winding and
indirect H2 cooling for the stator winding . The losses in the
remaining generator components such as iron losses,
friction and windage losses and stray losses are also
dissipated through hydrogen. The generator frame is
pressure resistant up to 10bars and gas tight and
equipped with end oil seals. At each end the hydrogen
coolers are arranged horizontally inside the stator frame.
Generator consists of the following components

A) Stator:

 Stator frame
 Stator core
 Stator winding
 Hydrogen coolers

B) Rotor:

 Rotor shaft
 Rotor winding
 Rotor retaining rings
 Field connection
 TURBINE
Steam Turbines are used to convert
the steam energy into mechanical rotational
energy. Major steam Turbines are

1. Reaction Turbines
2. Impulse Turbines

Here in RTPP, Reaction Turbines are

used.
 TRANSFORMERS

Types of transformers generally used when

supply is to be taken from grid and it is used for
the plant. Power transformer or generator
transformer is used to step up the generated
voltage and give it to transmission line. Unit
auxiliary transformer is used for providing power
to auxiliary system inside the plant, taking a part
of the generated voltage.
 Boiler

BOILER: A closed vessel in which water is

heated,steam is generated,steam
superheated,
• Boiler types
• Fire tube
• Water tube
• Other types : ( electric)
 FUEL
Coal is the most commonly used fuel in
thermal station. Coal occurs naturally in seams
and is the result of decay of vegetable
matter accumulated in the earth millions of
years ago having got transformed by the
action of pressure and heat. As mined raw
coal usually contains impurities such as pieces
of slate etc., With the result that some amount
of processing is required at the colliery before
it can be shipped.
 COAL HANDLING PLANT

Coal from the wagons is unloaded

using charger arm and wagon tripper, which
is driven by hydraulic systems. Raw coal is
taken on the MCB, from which it is feed to
the crusher. The coal is crushed into a size of
20mm. If any problem is occurs in one path,
the process is diverted to another path from
the motor control cabin itself.
 ASH HANDLING PLANT
A good ash handling plant should have large
capacity to handle clinkers, boiler refuse, soot and
dust with minimum attention of operators. It should be
able to handle hot and wet ash effectively. The major
dust and ash collectors used in thermal power plant are
electrostatic precipitators. There are four groups into
which modern ash handling systems may be divided.
Those are:
1. Mechanical Handling System
2. Hydraulic System
3. Pneumatic System
4. Steam Jet System
 FANS

Fans are provided throughout the steam electric

generating unit to supply air on to exhaust flue gas to
meet the needs of various systems. In addition fans are
used for building heat and cold to prevent contamination
due to inter leakage & cooling for a wide variety of
equipment from lubricating oil coolers to mechanical
draft cooling towers.
 FANS
Power plant applications that receive the largest fans for
steam generation are:
Forced draft fan (FD)
Primary air fan (PA)
Induced draft fan (ID)

FD fans supply combustion air to the steam

generator, PA fans normally handle relative low-flow
and very high pressure differentially. ID exhaust
combustion products from the steam generator. ID
fans exhaust combustion ID fans control furnace
pressure.
 Mills
Mills are of two types
Bowl mills
Ball mills
Bowl mills have low capacity than that of ball mills.
Hence for a high capacity power plant,Ball mills are commonly
used.

Mill is a long cylinder having liners on its inner periphery. With

a number of Iron balls. Coal is pulverized to a size of 200
microns.
Primary air fans are used to carry the pulverized coal from mills
to furnace through four cannels at each end.
 CONDENSER
The function of the condenser is to condense
exhaust steam from the main power cycle steam turbine.
The use of condenser improves the efficiency of the
power plant by decreasing the exhaust pressure of the
steam below atmosphere. Another advantage of
condenser is that condensed steam can be recovered
and this provides the source of good and pure feed
water to the boiler. There by reducing considerably the
water softening plant capacity. Air and non-condensable
gases are also removed from the steam when it passes
through the condenser.
CIRCULATING WATER PUMPS:
Circulating water pumps supply cooling water to
the required flow rate and head to the power plant
condenser and the plant auxiliary cooling water
heat changes.
CONDENSATE PUMPS:
These pumps pump the condensate water from
the condensate hot well to a deaerating heater.
BOILER FEED PUMPS:
A BFP is a pump, which supplies feed water
to steam generator for the production of steam.
DCS ARCHITECTURE
 Evolution of DCS
•Pneumatic Control System - Single Loop
Controllers, More Hardware, Less Accurate,
Cumbersome Maintenance.
•SLPC - Electronic Controllers, Single/multi
Loop, More Hardware
•DCS - Introduced in the ‘80s, Microprocessor
Based, Graphic User Interface, Interface With
Other Devices, Availability of Reports &
Diagnostics, User Friendly
 I/O Block Diagram
Field (Hazardous Area) Control Room (Non-Hazardous Area)

JB
Marshalling DCS
Rack

Transmitters
C/Vs etc.
 Process Control - Components
HARDWARE

•Transmitter, Control Valves etc.

•Cables, Junction Box.
•Barriers, Converters etc.
•Power Supply Modules
•I/O Cards & Processor
•Communication Modules
•System Communication Bus / Network
•Graphic Display Station – CRT
•Operator Interface – Keyboard/ Touchscreen / Mouse
etc.
 SOFTWARE - DCS
•System Configuration – Database Builder, Control
Configuration Etc.
•Graphic Builder
•History Builder & Report Writer
•Diagnostic Tools
•Logic Editor
•Control Language – User Programmable Software
 DCS ARCHITECTURE
Supervisory MIS
Computer Computer

INFORMATION NETWORK

Operator
ENGG. Consoles
Station

DCS COMMUNICATION BUS

COMMN.
I/F
Field
I/Os COMMN.
I/F

Marshalling I/O, PLC / Other

Rack Processor SYSTEMS
Rack
Instrumentation of the
Plant
 Temperature Elements
 Pressure Elements
 Flow Elements
 Level Elements
I. Temperature
 Definition:
 It is the Degree of Coldness or hotness or in
other word related to the kinetic energy of
molecules.
 Temperature generated by heat energy.
 Heat energy has unit of BTU (Brithish
Thermal Unit) or Calorie
Temperature (Cont.)
 Units:
 Fahrenheit (ºF), Centigrade (Celsius) ºC,
Kelvin ºK, Ranklin ºR
F= 5/9 x C + 32
C= 9/5 (F-32)
K= 273.15 + C
R= 459.7 +F
Temperature (Cont.)

212 100 373.15 671.7 Water

Boiling

32 0 273.15 459.7 Water

Freezing

-459.7 -273.15 0 0 Absolute

ºF ºC ºK ºR zero
Temperature
(Measurement)
 Thermocouple: Consists of two dissimilar
metals joined at one end and other end
connected to meter. When joined end (Hot
junction) heated, voltage will be produced at
the other end (Cold Junction).
Temperature
(Measurement)
T/C Type Chemical Range
Composition
J-Type Iron - constantan -196 to 760 deg C

K- Type Chromel – Alumel -190 to 1260 deg C

S- Type Platinum/Rhodium – -18 to 1760 deg C

platinum
T- Type Copper – Constantan -185 to 371 deg C

E- Type Chromel – Constantan -196 to 982 deg C

R- Type Pt87/Rh13 – Platinum -17.7 to 1704 deg C

Temperature
(Measurement)
 Resistance Temperature Detector (RTD)
 Heat Sensitive element prepared with carefully made
electric resistance.
 Used material: Platinum, Nickel, Iron, Salver
 In our plant most of RTDs used are Pt100
platinum resistance= 100 ohm at 0 degree C
 As temperature rises, resistance increases.
Temperature
(Measurement)
 Thermostor:
 Very small Solid thermo-electric devise
made of solid semiconductor of various
metal oxides.
 The electric resistance of thermostor
decrease with an increase in temperature.
 II. Pressure
 Definition:
 Defined as the normal force per unit area acting on
surface of an object.
 P=F/A
 Units:
 Pa, psi, inches of mercury, inches of water, BAR,
atm, Kg/cm2
 Pressure (Cont.)
 Scale of measurement:
 Gauge Pressure Scale
 Absolute Pressure Scale
 Vacuum Pressure Scale

Pg= Pa - Atmospheric Pressure

 Pressure (Measurement)
 Manometers:
 Used for the direct measurement of pressure and
vacuum.
 U-Tube Manometer
 A glass of U- tube shape, partially filled with liquid.
 The zero is connected to the scale when both ends of the

U-glass opened to atmosphere.

 P1 P2

U-Tube Manometer
 Pressure (Measurement)
 U-Tube Manometer (Cont.)
 When applied pressure at one end of the tube, difference
in level will occur:
 P2-P1=. h

 : Density (lb/in3)
h : height (in)
P2-P1: Pressure (psig)
 Pressure (Measurement)
 Well Manometer (Single Leg):
 Used for low pressure application with higher accuracy
from the U-Manometer.
 P2-P1=  (1+A1/A2) h

P2
A1
A2 P1
h
zero line
 Pressure (Measurement)
 Inclined-Tube Manometer
 Used for extreme low pressure application
 P2-P1=  (1+A1/A2) L. sin 

P2
A1 
A2 P1
h L
zero line
 Pressure (Measurement)
 Pressure Element
 Mechanical devices changed its shape when
pressure is applied
 The pressure elements sometimes called elastic
deformation pressure element
 Each type has its range of operation pressure.
 Pressure (Measurement)

Pressure elements Minimum range Maximum range

i)Diaphragm 0”to 2” water column (WC) 0 to 400 psi
ii).Bellows 0”to 5” water column (WC) 0 to 800 psi
iii)Capsule 0”to 1” water column (WC) 0 to 50psi
iv)Bourdon tube 0 to 12 psi 0 to 100,000 psi
v)Spiral 0 to 115 psi 0 to 4,000 psi
vi)Helix 0 to 50 psi 0 to 10,000psi
 Pressure (Measurement)
 Pressure Transducers
 Elastic deformation element joined to electrical
device.
 Changes in resistance, inductance, or capacitance
 Pressure (Measurement)
 Strain Gauge:
 Fine wire in form of grid.
 When the grid distorted, resistance of the wire will
change according to:
R=K. L/A
K : Resistively of the metal
L : Length of wire
A : Cross sectional Area
Pressure (Measurement)

Grid Wire
Lead
wires

Ceramic or
paper backing

Strain Gage
 Pressure (Measurement)
 Strain Gage (Cont.)
 As Strain Gage is distorted by the elastic
deformation length will increase and area will
reduced.
 Resistance will increase accordingly.
 Pressure (Measurement)
 Inductance Type
 Consists of Coil, Movable Magnet core, and elastic
deformation element.
 AC current pass through coil.
 As the pressure varies the elastic deformation, the
magnet core will move through the coil.
 This will change the inductance.
Pressure (Measurement)

Coil
Non Conductive Tube

Movable Iron Core

 Pressure (Measurement)
 Capacitance Type
 Consists of two conductive plates, dielectric, and
diaphragm.
 As the pressure increases diaphragm will move the
plate changing the capacitance.
 Flow (Measurement)

 Flow rate and flow quantity of

materials is made primarily for
determining the proportions of
materials introduced to the
process.
 Method of measurements:
• Head Elements
• Area Elements
• Quantity Velocity Elements
 Flow (Measurement)
 The following properties are
important for the flow measurement:
• Pressure: Force applied on Area
• Density : Weight divided by volume
• Viscosity : Resistance to flow
• Velocity : Speed of the fluid. It determine
the behavior of the fluid.
 Flow (Measurement)
 Flow Types:
• When the average velocity is slow, the
flow is called laminar, i.e fastest layers
at the center and the slowest at the
edges
• When the average velocity increases,
the flow is called turbulent.
• The measurement of laminar, turbulent
flow is as per Reynolds number
Flow (Measurement)

Laminar
Flow

Turbulent
Flow
 Flow (Measurement)
 Most Flow are design to work in
turbulent flow
 Units of Flow:
• lb/Hr, Kg/Hr, T/Hr: mass flow
• cfm, M3/H, KNM3/Hr: Volumetric Flow
 Flow Measurement
 Head Flow Elements
• When the liquid flows through a
restriction, the energy converted kinetic
energy.
• The pressure will drop and velocity
increases.
Q C  P
C: constant
P: Differential pressure across
restriction
 Flow Measurement
 Head Flow Elements
• Orifice Plate: the loss in the pressure is
more that other type of flow measurement.
 The selection of orifice plate based on ratio of
bore diameter to (d) to inside pipe diameter
(D). = d/D
 best accuracy is when: 0.2 <  < 0.6

 Taps used :

• Flange tap
• Pipe taps
• Vena Contracta tap
 Flow Measurement
• Venturi tube: expensive and the most
accurate type >0.75
 Pressure recovery is excellent

Upstream Tap Downstream Tap

 Flow Measurement
• Flow Nozzle: cheaper than venturi,
 accuracy less than venturi
 >0.75

 pressure recovery is not as good as venturi

Upstream Tap Downstream Tap

 Flow Measurement
 Variable Area Flow Meter
• Rotameter: consists of tapered, vertical
glass consists of float.
• Flow will carry the float from bottom to
top through variable area glass.
Q  A  2 gh
A: cross sectional area of the glass
g: gravitational acceleration
constant
h: the height of the float.
Variable Area Flow Meter
Out

Float

In
 Flow Measurement
 Quantity Flow Measurement
• Positive displacement
 Measure the total quantity of the flow
 separate the liquid into discrete volumes

 Total of these volumes in time period will

give the total flow amount

• Mass Flow meter:
 measurement of the weight per unit time.
 Continuous measurement of density
 Level
• There is two ways of measuring level
– Direct level measurement
• by varying liquid will get the level
– Indirect level measurement
• by using a variables which changes with the liquid
level changes.
 Level Measurement
• Float
– special material designed to follow the level or
the interface level of a tank
– The specialty is the density of the float shall
be always touching the desired measurement
level.
– As the level increases/decreases, float will
follow and causing a connecting tape to
change its length.
 Level Measurement
• Displacer
– Archimede’s Principle: a body wholly or partially
immersed in a fluid is buoyed up by a force equal to
the weight of the fluid displaced.
– The level is measured by detecting the buoyancy
force of an immersed displacer
– The major difference between float and displacer is
that displacer is partially or totally immersed, while
float is always floating in the surface of the level.
Flexible
Cable

Displacer Float
 Level Measurement

• Differential pressure
– h = P/ (British unit) inches
– h= P/(g.) (SI unit) meters
– as level changes differential pressure will
change accordingly.

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