1

BRIEF HISTORY OF PLANT

Ever widening gap between the power demand and its availability in the
state of Punjab was one of the basic reasons for envisaging the thermal
plant at “Lehra Mohabbat” Distt. Bathinda. The other factors favoring the
installation of this thermal were low initial cost and less generation
period as compared to hydroelectric generating stations, its good railway
connection for fast proximity to load center. Guru Gobind Singh thermal
plant is Government undertaking (under P.S.E.B.)
Initially it was going to set up at Bathinda under
GNDTP but the air force personal restricted its set up at Bathinda hence
plant site is shifted to Lehra Mohabbat about 22Km from Bathinda city.
Later this plant was approved as a separate autonomous body with its
name as Guru Hargobind Thermal Plant.
The construction of the plant commenced in 1992 and
its unit started working in December 1997. Its second unit commenced in
August 1998. The main companies whose technology pawed the way of
this plant are TATA Honeywell & BHEL in turbine and boiler control
.The total set up cost of the plant is 1200 crores and the capacity of the
plant is 2*210 =420 MW. The over all efficiency of the plant is 95%.
The power availability from the plant now meets 20-25% of
the total power requirement in Punjab. It has gone a long way in ushering
prosperity in the state by emerging a large number of agricultural
pumping sets, more industrial connections, 100% rural electrification,
increased employment potential reliability and improvement in continuity
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of supply and system and removal of power cuts to a great extent. It has
also led fast development of environment in area around District
Bathinda by providing employment to about 3000 persons. Two new
units of 250MW each are going to be commissioned soon, sanctioning of
which has already being done.

The following considerations have to be examined in detail before

selection of site for a plant: -
 Availability of fuel such as coal.
 Ash disposal facilities.
 Space requirements.
 Nature of land.
 Most important availability of water.
 Availability of labour.
 Transport facilities.
 Public Society problems such as pollution.
 Development of backward area.

PROFILE OF THE PLANT

OWNER BOARD Punjab State Electricity

Board

NAME OF THE PLANT Guru Gobind Singh Thermal Plant

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SITE LOCATION Between 129 Km and 132 Km,

Milestone on Bathinda-Barnala
Road

MAIN COMPANIES TATA HONFY WELL and

EVOLVED BHEL

CONSTRUCTION IN 1992
STARTED

COMMENCE MENT IN DECEMBER 1997

OF 1ST UNIT

COMMENCE MENT IN AUGUST, 1998

OF 2ND UNIT

TOTAL SET UP COST 1200 Crores

TOTL CAPACITY OF 420 MW

THE PLANT

TOTAL UNITS IN 2
THE PLANT
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GNERATION COST 112 Paisa/kW

OVERALL EFFICIENCY 95%

OF THE PLANT

HEIGHT OF CHIMNEY 220 Meters Multi Flue

SOURCE OF WATER Bathinda Branch of

Sirhind Canal

POWER DISTRIBUTION

Electric Power Generated here is send to various sectors through

distribution center. This is the main product of the plant, which is our
nations wide requirement. Electric Power drives all our factories,
industries, Railways, Domestic equipment etc. Overall our life is
dependent on the electric power now days.
Distribution center distributes power from here to Barnala
Sub Distribution Mansa, Bathinda, Delhi, Ludhiana and Duri as per
requirements.

RAW MATERIAL AND THEIR SOURCES

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Power generation is using coal, HFS etc. as burning fuels for the
generation of steam from demineralised water.
Coal coming from West Bangal & Bihar via Rail wagons
of 3800 Kcal/kg & 35% ash contents as the minimum requirement with
rate of rupees 680/-p.tone. &4000 Tons per Day in quantity.
Water is taken from Sirhand canal by the tunnel link of
underground 2600mm dia pipes, which is collected in water pond of 150
arcs area & capacity 100000 cubic meters.

BASICS OF A THERMAL PLANT

In a thermal plant, heat energy is converted into mechanical energy of

turbine that is further converted into electrical energy with the help of
generator.
A schematic view of the simplest steam power plant
is shown in fig. A that is on next page.

The three main processes in the diagram are: -

 Process AD: - Water is admitted to the boiler, raised to boiling

temperature and then superheated.
 Process DF: - The super heated steam is fed to the turbine where
it does work on blades and rotates it.
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 Process FA: - Heat rejected to the condenser. Circulating water

carries a very large proportion (40-60% of total heat).

The basic cycle of a steam power plant considered

above is called the RANKINE CYCLE.
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RANKINE CYCLE ON TEMPERATURE

ENTROPY DIAGRAM

The Temperature Entropy (T-S) diagram is the most useful diagram

for illustrating certain fundamental points about steam cycle. Ideal
condition for steam cycle on a T-S diagram is shown in the fig. That is on
the page no.2
At point ‘A’ the condense is at boiling temperature
corresponding to the back (condenser) pressure. Heat (sensible) is added
to this water to raise its temperature and pressure. At the point B, it
reaches it saturation temperature. Evaporation begins at point B. Heat
(latent because no rise in temperature between B & C, as evident from
the diagram) addition continues. At C all the water evaporates and super-
heating commences. This is shown by the curve CD and at D, the
superheated temperature is achieved.
Steam then expands as it enters the turbine and rotates it, as
shown in the line DEF. At point E there is no super heat left in the steam
and so from E to F there is increasing wetness. At F steam is passed out
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to the turbine to the condenser and condensation of steam takes place as

represented by the line FA. At point ‘A’ the steam has all been
considered and condense is a boiling temperature ready to begin another
cycle.

To summaries the above:

AB - Heating of feed water (i.e. sensible heat

Addition)
BC - Evaporation of water in boiler (i.e.
Latent heat addition)
CD - Superheating of steam (i.e. superheat
Addition)
DF - Expansion of steam in turbine, point E
Donates demarcation between super-
heated and wet steam.
FA - Condensation of steam in condenser.

PROCESS OF POWER GENERATION: -

A generating unit of thermal plant consist of boiler unit, a turbine with

accessories, a generator, a unit transformer and other equipment all
arranged to operate as complementary part of a complete monolithic set.
The plant
Overview diagram, which shows the process of generation of electricity,
is on the next to next page.
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ELECTRICITY GENERATION PROCESS

EXPLANATION

The coal travels by the conveyer belts from the coal handling
plant to the coalbunkers from where it is fed into pulverizing mills; which
grind the coal into powder. The powder coal is carried from the mill by
steam of air heated air in the air heater driven by primary air fan (PA) to
boiler burners where it is blown into the furnace and burns like a gas a
force draft fan provide addition controllable to the burners to assist
combustion. The product of this combustion is dust and ash. (Ratio of 5to
1) the ash to the bottom of the boiler and is periodically sluiced to mash
setting pits .The dust carried in the fuel gas to the precipitators where it is
extracted by high voltage electrodes. The dust is then conveyed to
settling lagoons or removed by the road for safe. The fuel gas passes by
an induced draft fan (ID) to the chimney. The heat released by the
burning coal is absorbed by long length of tubing which forms the boiler
valves. Inside the tube extremely pure water that is known boiler feed
water is converted by the heat into steam at high pressure and
temperature. The steam is then superheated in further tubes and passes to
the high pressure (H.P) turbine where it is discharged through the nozzle
into the turbine blades. The energy of the steam striking the blades make
the turbine rotates after passing through the high-pressure turbine. The
steam is returned to the boiler for reheating before passing through the
intermediate pressure turbine (IPT) and to the low-pressure turbine (LP).
Coupled to the turbine shaft is rotor of the generator, a large cylindrical
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electromagnet, so that when the turbine rotor rotates, other rotor rotates
with it. The generator rotor is enclosed in the stator; which consist of
large coils copper bar in which electricity is produced by the rotation of
magnetic field created by the rotor. The electricity from the stator
winding goes to a transformer; which increase its voltage so that it can be
transmitted over the power lines into grid system. Mean while, the steam
that is exhausted its useful energy in turning the turbine is turned back
into water in the condenser so that it can be
Used again in the boiler. Before entering in the boiler at the economizer
the water is pumped by condense extract pumps heated in the low
pressure (L.P.) heaters, deaerated in the deaerator increased in the
pressure by boiler feed pumps and heated further in high pressure (HP)
heaters. The water passes through the economizer to the steam drum then
up through the furnace wall–tubing before returning to the steam drum
for steam separation. The steam leaves the drum and heated further in the
super heater on its way to the HP Turbine. The condenser contains miles
of tubing’s through which the cold water is constantly pumped.
The diagram showing this whole process is shown on page
no. 11& page no. 12

Plant overview

COAL PLANT
Conveyer belt

BOILER BUNKERS

PULVERISING MILLS
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BOILER BURNER
FD Fan

COMBUSION
Dust
Ash

CLEARED FUEL GAS PASS TO CHIMNEY

VIA INDUCED DRAUGHT FAN

COAL BURN

Heat released

BOILS WATER WHICH GIVES STEAM

STEAM IS SUPERHEATED

PASSES TO H.P TURBINE

Continue On Next Page

CONTINUED FROM THE LAST PAGE:-

EXHAUSTED STEAM CONDENSER USED AGAIN IN

ENERGY BOILER
Steam
TURBINE BLADES WATER IS PUMPED

CAUSES TURBINE HEATED IN LP HEATERS

TO ROTATE
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DEAERATED IN
STEAM IS RETURNED TO DEAERATOR
BOILER FOR REHEATING

PRESSURE INCREASES
TIRBINE SHAFT IS COMPLED BY BOILER FEED PUMPS
TO ROTOR OF GENERATOR

HEATED IN HP
GENERATOR ROTOR IS
HEATERS
ENCLOSED IN STATOR

ECONOMIZER
ELECTRICITY IS PRODUCED AT
STATORWINDINGFROM WHICH
IT GOES TO TRANSFORMER
STEAM DRUM

POWER IS STEPED UP
BY TRANSFORMER STEAM IS HEATED
IN SUPERHEATER
Power Lines

GRID SYSTEMS
HP TURBINE

PLANT OVERVIEW

BLOCKS DISCRIPTION

SUPERHEATER (SH)
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Super Heater (SH) is a plain tubular, non-drainable vertical in line spaced

type, arranged for parallel flow. This super heater (SH) is located in the
horizontal path after reheater. Next to Super Heater is Reheater System.

REHEATER SYSTEM (RH)

The reheater section is the single stage; spaced type, continuous loop, and
plain tubular, non-drainable, vertical in line spaced type, arranged for
parallel flow.

ECONOMISER SYSTEM (ECON)

The economizer system is a single block unit, is of continuous loop plain

tubular, drainable horizontal, in line arrangement with water flow
upwards and gases flow downwards. The economizer tubes are
suspended from economizer intermediate header, using ladder type
supports.

DEAERATOR (DEA)

The deaerator (DEA) is provided to remove dissolved corrosive gases

from feed water that goes to the boiler. It prevents internal corrosion of
boiler tubes. The oxygen is reduced to untraceable limits by mechanical
means in the condense living the deaerator.
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BOILER FEED PUMP (BFP)

Boiler feed pump (BFP) is very important auxiliary of the powerhouse. It

has to take supply of water from the deaerator, and supply it to boiler
drum against the positive drum pressure.

MILLS

Bowl mills have been installed from pulverizing the raw coal. The coal of
maximum size of 25 mm is received in raw coalbunkers from Coal
Handling Plant. From the bunker, this coal is fed into the mill through
Raw Coal Feeder. Regulating the speed of the Feeder can control the feed
of the coal mill.

CONDENSER (COND)

The condenser (COND) is a box type double pass with divided water box
design that facilitates the operation of one half of the condenser while the
other half is under maintenance. The steam space is of rectangular cross
section to achieve optimum utilization of the enclosed volume for
necessary air-cooling section at the center from where air and non-
condensable gases are drawn out with the help of air evacuation pumps.
The circulating water enters the water boxes from bottom and then
travels through several tubes and leaves the condenser through upper
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water boxes in two distinct paths. Next to condenser is condensate

extraction pump (CEP).

CONDESATE EXTRACTION PUMP (CEP)

There are two 100% capacity condensate extraction pumps (CEPs)

provided in the system. Normally, one condensate extraction pump runs
and other is kept as stand-by. These pumps are of vertical and centrifugal
canister type with the driving motor. Condensate extraction pumps have
five stages.

GLAND STEAM COOLER (GSC)

The gland steam cooler is used to condense the steam extracted from
turbine glands and to maintain slight vacuum at the turbine glands to
avoid steam leakage to atmosphere from turbine glands. It is a single pass
heat exchanger with the main condensate entering from one end and
leaving from the other end. Air steam mixture passes over the tubes in
zigzag path due to number of baffles and thus steam is condensed there-
by heating the condensate inside the tubes.

DRAIN COOLER (DRN CLR)

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Drain cooler (DRN CLR) is provided to sub cool the drains coming from
Low Pressure (LP) Heater to improve the cycle efficiency by heating up
the condensate flowing through the tube system.

LP HEATERS (LP HTRS)

The LP heaters (LP HTRS) are of the surface cooled type. They are
designed for vertical mounting. These heaters are of tube system
withdrawal type; these are of four-pass design. Condensate flows inside
the tubes while steam flows

Outside the tubes. The condensed steam is collected in the bottom of the
shell that is drained out.

H.P. HEATER (HP HTRS)

High Pressure heater is supplied heating steam from extraction 5 taken

from IP casing of turbine. The feed water enters first in this H.P heater
and after getting heated goes to High Pressure (HP) heater 6. The feed
water flows through the tubes from coldest zone to the hot most zones
before it leaves the heater. The steam flows from hot most zones to
coldest zone and the drain normally goes to deaerator.

ROTARY AIR HEATER (RAH)

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The basic principal of operation of Rotatary Air Heater (RAH) is the

same as the liung storm type except that the elements are stationary and
the air hoods rotate with. In the gas pass at approximately 1 rev./min. The
axis of rotation may be vertical or horizontal but again and for similar
reasons the vertical spindle is preferred. The drive is normally through an
electric motor operating a pinion that meshes with the rack on the outer
rim of the hood assembly.

FORCED DRAFT FANS (FD FAN)

To take air from atmosphere at ambient temp. To supply essentially all

the combustion, air can either be seized to overcome all the boiler losses
(pressurized system) or just put the air in the furnace (balanced draft
units).

INDUCED DRAFT FANS (ID FANS)

Used only in balanced draft units to suck the gases out of the furnace and
throw them into the stack. Handles fly ash laden gases at temperature of
125 to 250oC.

ELECTROSTATIC PRECIPETATORS (ESP)

The principles upon which Electrostatic Precipitators operates are that the
dust-laden gases pass into a chamber where the individual particles of
dust are given an electric charge by absorption of free ions from a high
voltage DC ionizing field. There are four different steps in the
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precipitation viz., ionization of gases and charging of dust particles,

migration of the particle to the collector, deposition of charged particles
on the collecting surface, dislodging of particles from the collecting
surface.

VARIOUS CYCLES INVOLVED IN POWER

GENERATION

PRIMARY AIR CYCLE: -

The primary air, generated by PA (primary air) fans, is used to carry the
pulverized coal from the coal mils to the furnace.
The Primary Air (PA) fans are two in number. A header called
the PA fan duct of the air is made and two tapings are made from this
header. One is passed through the AIR PRE-HEATER A and B, which,
using the heat of the outgoing flue gases, heats the air, now called the hot
primary air. This hot primary air is now divide into six parts A to F and
then sent to the six coal mills by making a hot primary air header.
The other tapping of air called the cold primary air is also
made into a cold primary header and then divided into six parts A to F to
be sent into six mills.
Now lets consider the action of primary air on the mills by
considering, say, mill A. Hot primary air A and cold primary air A pass
through respective valves in their pipes before entering the coal mill. The
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valve is installed as the inlet flow temperature is to be maintained at

>175ºC and the flow of the air flowing in the mill is to be at 54-
tons/hr.the outlet temperature is to be maintained at >65ºC &< 10ºC.
From the mill, four feed outlet are taken, carrying the coal to
furnace. As these are six mills, so there are 24 feeds to furnace.
The feed from each mill enters the furnace at 4 different
corners but at the same elevation or height. The feed from other mills
also enters the furnace at corners but at different elevations.
All the feeds from the mill open equally. Now consider
only one corner of the furnace. The feed from mill A enters the corner of
the lowest elevation and those from mill F at highest elevation. The other
feed is between them. In between feeds A & B, C& D, E & F, there are
oil guns called feed AB, CD, and EF respectively. Below A and above F,
There are auxiliary air inlets in the furnace. The primary air cycle is
shown on the next to next page.
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SECONDARY AIR CYCLE: -

The forced draft fans are used to generate the secondary air, which is
used to help in the ignition and burning of the coal in the furnace. A
common header is made of the two FD fans (A&B) and this passed
through the two air pre-heaters, which heat the air using the heat from the
flue gases, so that the cold air doesn’t bring down the temperature of the
furnace. The secondary air for combustion is preheated up to 317 oC by
means of regenerative air-heaters (Rotary Air Heaters). The air heater air
out ducts are interconnected to provide a balanced air flow to the furnace
and to make it possible to operate the unit at reduced load if one fan is
out of service.

Distribution of secondary air to Wind Box compartments is controlled by

the secondary air dampers. The steam coil air pre-heaters (SCAPH) one
each at the outlet of FD Fans & before RAH has been provided to avoid
the corrosion of RAH by increasing the temperature of secondary air
entering the RAH when the boiler is initially lighted up. The secondary
air path is shown in fig. That is on the next page.
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Air I/l PA RAH MILLS

FAN A&B A-F
A&B

PRIMARY AIR CYCLE

FURNACE

FD SCAPH RAH
Air I/l FAN A&B A&B
A&B

SECONDARY AIR CYCLE

AIR CYCLE

FLUE GAS CYCLE: -

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Flue gases travel upward in the furnace and downward through the rear
gas pass to the economizer and air heaters. In the economizer, the some
heat of flue gases is utilized to heat the feed water before it goes to drum.
Further in the air heaters, the residual heat of the flue gases is utilized to
pre-heat the secondary and primary air. From the air heaters, the gases
pass through the electrostatic precipitators (ESP) and induced draft fans
to the stack. Interconnections of the gas ducts at inlet and outlet of
electrostatic precipitators are provided.

RAH ID FAN
FURNACE ESP A, B, C
A&B

CHIMNEY
OR
STACK
FLUE GAS CYCLE
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WATER CYCLE: -

The steam after working in three casings of the turbine i.e. HP, IP & LP
casings is condensed in the surface condenser installed just below the LP
exhaust hood. The condensate is collected in the bottom portion called ho
well from where it is pumped into the Deaerator by condensate extraction
pump (CEP) through different heating stages through which condensate
flows and get heated up gradually before finally reaching the Deaerator.
The various heating stages are Gland Steam Cooler, Drain Cooler, and
LP Heater (1, 2, 3) Deaerator. The approximate temperature rise of
condensate after passing through above heating stages is from 40/45 at
hot well to 166oC at the Deaerator (at full load).

The condensate coming from LP heaters passes the tubes of vent

condenser. The steam transfers its heat to condensate flowing within the
tubes and gets condensed. The non-condensable gases along with some
steam go out of the equipment. The drain (condensed steam) is returned
to the deaerating header.
The condensate after leaving the deaerating header
enters the feed storage tank. From feed water tank, the boiler feed pumps
takes suction of feed water thorough booster Pumps and discharge is fed
to the boiler drum after passing through different heating stages viz. HP
heaters (5, 6) and feed water regulation station (FW REG STN).
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FM DM
M/U

steam COND. CEP GSC DRN

A&B CLR

LP
HTR’S

FW HP BFP DEA
REG STN HTRS 5,6 A, B, C

FURNACE

MAIN WATER CYCLE

STEAM CYCLE

Steam is that part of the whole process cycle in which the fluent is steam
i.e. part of the cycle containing steam. Steam is first of all generated in
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the boiler with the help of coal as a principal fuel. If it is not present in
the adequate amount or not of high purity then heavy furnace oil (HFO)
and light diesel oil (LDO) is used to produce heat in the furnace.
The heat energy supplied in the furnace is absorbed by the
water walls and gets heated up. This gives rise to the formation of steam
bubbles in the water walls and the risers. The cold water in the drum
there continuously displaces the moisture of steam bubbles and water by
destabilizing a natured circulation. With the help of super heater (SH)
the steam is super heated and passes to the HP Turbine. For high
efficiency, the turbine is divided into three stages viz. HP Turbine, IP
Turbine and LP Turbine. Now at the starting the temperature of the shaft
of the turbine is less and at once increase in temperature may cause ‘Sag’
in it therefore few cycles of heated steam passes through the HP BP so
that the conductor in the turbine may achieve the equivalent temperature
of the steam by this there will be no loss of heat due to temperature
difference. Through HP BP it again passes through the furnace and there
it reheats with the help of Repeater (RH) and then it passes to the IP
Turbine at a temperature of about 551oC . From here it passes through the
LP Turbine that rotates the coils of the generator and electricity has been
produced. Like HP BP, LP BP is present as a direct passage of heat from
IP Turbine to condenser where this steam is again changed into water.

MAIN STEAM CYCLE

HPT
FURNACE
HP BP
ECON SH

RH
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IPT

LPT
COND LP BP

GENER
ATOR

WORKING OF THERMAL POWER PLANT AT

G.H.T.P.

Coal received from collieries in the rail wagons is

mechanically unloaded by wagon tippler and carried by belt conveyor
system to crusher house underground. In crusher house the coal is
crushed up to 25mm. This coal is taken by belt conveyer to raw coal
bunkers near coal mill. The coal is then milled to powder form having up
to 0.5mm to1.0mm dia. There is a raw coal chain feeder that regulates
quantity of coal from bunkers to coal mill where coal is pulverized as
said above. That pulverized coal is then pushed to the boiler furnace by
pressurized primary air from corner feeders. This furnace have water tube
wall all around through which water circulates. Water is converted into
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steam by heat released by combustion of coal. The oils L.D.O.&H.F.O

are used in combustion of coal forced by forced draught fan. That air is
sent in the boiler furnace after heating in air heater by using the heat of
flue gases.
The greatly heated steam and water is sent to boiler
drum, where the water is separated from steam and the dry steam is sent
to the T.G.set, and the water is again sent to reheater and economizer.

The steam having 130km/m2 to144km/m2 pressure and 5400 c

temperature is sent to H.P turbine. Turbine is made from Germany which
uses high pressure steam and rotates at 3000rpm.The steam used in
H.P.Turbine is lost its heat up to 2400 c so to reheat i.e. to raise again the
temperature and pressure of the steam. The steam is passed through the
reheater and continuously sent to H.P&L.P turbine, made by B.H.E.L.,
rotated on the same shaft with 3000rpm. The steam from LP turbine is
taken out in a vacuum condenser having (-) 0.9kg/cm2 vacuum. Here the
steam is condensed by cold water pipes ciculation.The condensed steam
in form of hot water is put into the hot wall. From where it is again feed
into the boiler drum through the deaerator, LP heaters, HP heaters, BFP,
Economiser etc. The condensating water, which is used to condense
steam, takes heat from steam and it becomes hot. That hot water is taken
to cooling tower where it is dropped from 10m heights to cool water by
using natural air draught. This circulation is made by C.W.pumps
And cooling is done up to 100 c.
The products of combustion of furnace charge are
flue gases and ash. About 20%of the ash falls in the bottom ash hopper of
 28

the boiler and is removed mechanically by mixing with water. The

remaining ash carried by flue gases is separated in the Electrostatic
Precipitator where the ash is electro statically evacuated

And this dry ash is dumped in the ash disposal area. The cleaned flue
gases are left to the atmosphere through 220m high chimney using
I.D.Fan.
The turbines are coupled to the same shaft upon
which the generator is coupled. The Three phase generator produces 3-
phase supply and which is pumped to the power grid system through
generator transformer by stepping up the voltage which is further send
for distribution.
The raw water is taken from ‘Sirhind’
Canal to ponds and after that some amount of water goes to the boiler
through D.M. plant and the remaining water is clarified and used for the
cooling purposes.
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 30

SYSTEM DESCRIPTION

G.H.T.P.Thermal Power Plant consists of various systems. These are the

following systems: -
 Coal Handling System.
 Fuel oil system
 Ash handling system.
 D.M. Plant.
 Emergency Power supply system.
 Control & Instrumentation system.
 Data Acquisition system.
 Power supply distribution system

COAL HANDLING SYSTEM

G.H.T.P.Thermal Plant is coal-based power plant. The annual

requirement of coal for 2 units based on specific fuel consumption of
0.60 kg/kwh is 1.381 million tones .The conveying and crushing system
will have the same capacity as that of the unloading system 1000
TPH.The coal comes in the coal plant in large pieces. The coal is fed to
the primary crushers, which reduces the size of coal pieces from400mm
to 150mm size. Then the coal is sent to the secondary crushers through
forward conveyors be crushed from 150mm to 20mm as required at the
mills. Then the coal is sent to mills through coalbunkers .In mills coal
becomes in powder form, which is sent to the boiler with the help of
priamary air fan. The coal is burnt in the boiler. Boiler includes the pipes
 31

carrying water through them. Heat produced from the combustion of the
coal is used to convert water in pipes into steam. This steam generated is
used to run the turbine. When turbine rotates the shaft of generated which
is mechanically coupled to the shaft of the turbine get rotated and so 3
phases electric supply is produced.

FUEL OIL SYSTEM

Fuel oil is normally used for start up and for flame stabilization at low
load. Initially in the boiler either L.D.O. or H.F.O. is combusted before
the combustion of the crushed coal from the mill.
Light Diesel Oil (L.D.O.) does not require preheating but
Heavy Fuel Oil (H.F.O.) requires preheating because H.F.O. is very
much viscous.
L.D.O. or H.F.O. are used initially because this oil has
less heat of combustion then coal. Heat liberated from the combustion of
these oils is used for starting combustion of coal as soon as coal starting
combustion L.D.O. and H.F.O.is stopped and coal is supplied
continuously from the fuel guns in to the boiler.
The H.F.O. is preheated by using the heat of burnt
gases, which is coming from boiler of the 2nd Unit through Chimney.

ASH HANDLING SYSTEM

When the coal is burnt in the boiler nearly 35% of the ash is liberated in
the addition with another burnt gases. These ash and gases are coupled
 32

out by the reduce draft fan from the boiler E.S.P. is between the boiler
and I.D.Fan. E.S.P. contains charge electrodes that attract the ash
particles and the collect ash this ash is sent for disposal.

DEMINERALISED PLANT (D.M)

A Demineralised water treatment plant is provided for supplying make up

water to the boiler.
Water as it occurs is never pure as whatever may be
the source always contain impurities .the major impurities of water are: -
 Non-ionic & undissolved
 Ionic &dissolved
 Gaseous

In the DM plant these impurities are removed chemically &

Demineralised water is sent to the boiler.

EMERGENCY POWER SUPPLY SYSTEM

For the safe shut down of the plant under emergency conditions i.e. in the
case of total power failure diesel generating sets are purposed to be
installed for meeting the power requirements of the essential auxiliaries.

CONTROL&INSTRUMENTATION
 33

The function of the control & instrumentation system is to add the

operator in achieving the safe and efficient operation of the unit. The
operator is to be provided with the adequate information considered
essential for start up, normal operation, planned shut down and
emergency shutdown of the unit.
Centralized control of the boiler &turbine
generator unit from a centrally located Unit Control Board (UCB) room
is envisaged. It would be possible
To start or to stop all electrically driven unit auxiliaries &power operated
valves and dampers from UCB expect where recommended, otherwise,
by the main equipment suppliers.

DATA ACQUISITION SYSTEM

In line with the modern practice of centralized monitoring and control of

large capacity power plants Data acquisition system (DAS) shall be
provided for monitoring and logging of different parameters of steam
generator, turbine, important temperature points of H.T & L.T motors,
generator & other auxiliaries of the unit.
The system shall monitor, log, the various
parameters at different time e.g. at the time of start up, shut down, normal
run sudden load throw off positions.
The electronic system of DAS shall be of high speed and equipment with
alphanumeric and trend display CRT and alphanumeric logging printer.

POWER SUPPLY DISTRIBUTION SYSTEM

 34

Power supply/control supply panels with adequate no. Of spare feeders

shall be provided to meet the requirement of primary instruments,
secondary instruments, controls panels, DAS, sequential control system
protection and interlock system. Suitable arrangement for automatic
changes over from normal supply to stand by supply and provision of
uninterrupted power supply (UPS) to meet the essential load
requirements shall also be provided.

TDC-3000

TDC 3000 organized by process plant instrumentation and control needs

flexibility. Before going in detail of the TDC-3000 (DCS) we should
familiar with the following objects.

AREA UNIT POINT CONCEPT: -

In TDC-3000 plant instrumentation is classified into areas and plant can

be sub-divided into max. 10 areas.
Collection of points on geographical or functional
sets is identified as units, which in terms are assigned to respective plant
area.
In one area max. 36 units can exist.

Area boiler subdivided into 5 units.

 35

 Feed water system (FW)

 Steam system (ST)
 Flue gas system (FG)
 Combustion air system (CA)
 Fuel system (FU)

Each unit will have respective set of process data points.

AREA UNIT POINT DIAGRAM

POWER PLANT

BOILER TURBUNE

FU ST FG CA FU
AA
AA
TIC FIC A
100 100
 36

TIC 100and FIC100: -

Points belonging to steam system unit of boiler area. Parameters of

process points of the total plant (all areas) can be viewed on any of the
universal station (with operating and universal personality), but process
parameter manipulation and alarm reporting are area specific.

ALARMS AND MESSAGES: -

Alarm and messages will only reported for the points, which are
belonging to the signed units. Whose area database is currently present in
the universal station? Alarm acknowledgements console wide function.

MANIPULATION OF PROCESS PARAMETERS: -

These are at the operator accessing level. Manipulation of parameters of

the process points will be allowed only for the points, which are
 37

belonging to the assigned units, whose area database is currently present

in universal station.
Manipulation of parameters of the process points that
are not belonging to the assigned unit to the area database currently
present in the universal station, will be allowed only at the access level
higher than that of operator’s access level.

ABOUT THE AREA UNIT POINT ORGANISATION: -

1.CONSOLE STATUS: - Unit display target is used to determine units

configured and assigned to the area database present in the universal
station.

2.SYSTEM MENU:-Organization survey menu target to determine the

points attached to individual units of the area.

WHAT IS TDC3000: -

Total distributed control system (TDC) 3000 is a Honeywell make

DISTRIBUTED CONTROL SYSTEM.

WHAT IS DISTRIBUTED CONTROL SYSTEM:

Functionally and physically separate automatic process controllers,

process monitoring and data logging equipment, connected with each
 38

other to share relevant information for optimum plant control is called

DISTRIBUTED CONTROL SYSTEM.

HOW DCS CAME IN TO EXISTANCE?

Customer in process industry resulted in advancements in control and
instrumentation(C&I) technology. This advancement and their
advantages and disadvantages are shown in fig.
 39

Development of (C&I) technology from pneumatic to electronic

equipment was itself a very big change. In electronic C&I equipment,
various functional blocks were used to function under vinter dependent
circuits and control logic.
At this stage these functions were interconnected by signals
through multiple cables.

Application of microprocessor and digital

communication technique made it possible to distribute the C&I
equipment distributed geographically and functionally, reducing multiple
cable into single cable. This inter connection of processing function
blocks of a system is termed as a network (N/W)
 40

The signal level and states previously used through multiple cables are
now digital information packets, multiplexed in time, around the N/w,
sent and received by connected functional processors.

Further advancement allowed the distribution of C&I system of various

type of function n/w like: -
 Process N/w
 Supervisory N/w
 Plant information N/w

Plant wide C&I automation dependent on these N/w’s, emerging as a

DCS.
The important benefit of DCS, which is making it popular
is the fact that even failure of processor or a N/w will not result in failure
of other processors or N/w’s of the system respectively.

WHAT ARE THE FUNCTIONS DISTRIBUTED

AROUND A DCS?
 41

Following diagram shows the function blocks in a DCS with their use:

WHAT IS THE MAIN BENEFITS OF DCS OVER

CONVENTIONAL C&I EQUIPMENT?
 42

 Reduction in cabling in control room.

 Physically and functionally separate modules.
 More uniform operations and tighter controls.
 Excellent information management.
 Better integration of plant controls.
 Considerable reduction over maintenance efforts.

WHEN &FROM WHOM THE FIRST DCS WAS

MADE AVAILABLE?

First DCS came in 1974 from HONEYWELL. It was named then TDC
2000 (total distributed control 2000). The communication link in TDC
2000 is called DATA HIWAY.

HOW TDC 3000 THEN CAME INTO EXISTANCE?

AND HOW IT IS ORGANISED?
 43

Further advancement resulted in release of TDC3000 in 1984. This now

release of DCS from HONEYWELL contained new Supervisory LOCAL
CONTROL NETWORKK (LCN).

EARLY TDC 3000 SYSTEM ACHITECTURE: -

HONEY WELL TDC 3000 is a data acquisition and control system that
can be tailored to meet the user specific requirements. It can be small
system with just a handful device, or it may be highly complex system
 44

with hundreds of devices and several kinds of communication networks

interconnecting these devices.
The LCN connected to UNIVERSAL STATION (US) is
used for man-machine interface and HISTOY MODULE (HM) is used
for storage of process system related information.
Process connected controllers like BASIC
CONTROLLERS (CB) and ADVANCED MULTI FUNCTIONAL
CONTROLLERS (AMC) are linked to LCN through the process N/w
DH and an interface HIGHWAY GATEWAY (HG).
Further development introduced a new process N/w
UNIVEWRSAL CONTROL N/w (UCN) in 1989.The process N/w is
connected to LCN through NETWORK INTERFACE MODULE (NIM).
Capacity of NIM is higher than HG.

The new TDC 3000 system architecture after inclusion of UCN and
process connected boxes is shown in fig below: -
 45

APM and LM are the UCN connected automatic process controllers

In various process plants TDC3000 is practically
implemented with redundant communication medium (cables), gateway
and process controllers.

WHAT IS TDC 3000 PROCESS OPERATION:

This means, monitoring and operating the process plant using universal
station of TDC3000 system, this includes: -

 Calling various displays.

 Monitoring status, values, trends, modes and event on displays.
 Manipulating parameters.
 Responding to various alarms and messages.
 Taking various hard copies on printers.
 46

 Storing important process related information.

Sensors and actuators of various kinds from the process plant are
connected to process controllers through N/w’s; process information
(values, status, modes, alarms etc.) is made available on the US displays.
From US it is possible to manipulate direct actuator drive,
values and mode change of different parameter in automatic control
function, also various commands to controllers and other N/w’s
connected function blocks can be sent from the US.
Monitoring and operation of TDC3000 system itself is also
done at US. Along with process operation, system operation aspects are
also practiced in TDC3000 process operation session

UNIVERSAL STATION

Universal Station is the man machine interface of TDC3000 system. In

our subsequent session we will be learning and practicing above-
mentioned activities from US.

 US is a single window to the process as well as TDC3000 system

allow the operator both monitored and manipulate the process the
system.
 System configuration is also done from Universal Station.

Before operating TDC 3000 universal station we should be familiar with

the following concepts: -
 47

 Universal station equipment.

 Universal station personality.
 The Access level type of universal station for operating security.

DIFFERENT PERIPHERAL CONNECTED TO

THE UNIVERSAL STATION (U.S).

 Color video display monitor with touch screen facility.

 Operator’s keyboard.
 Electronic card rack.
 Engineer keyboard (optional).
 Cartridge/floppy drive (optional).
 Printer (optional).
 Trend pen recorder (optional).
 Video copier (optional).
 Track ball (optional).

DIAGRAM OF US IS SHOWN BELOW: -

 48

1.COLOUR VIDEO SCREEN DISPLAY MONITOR

WITH TOUCH FACILITY: -

 Consist of 48cm. (19-inch) high resolution colors CRT and associated

electronics. Each CRT has brightness and contrast thumb wheels and a
degaussing push button on the bezel. The color video display monitor
shows system displays and process displays.

 The touch screen option on the color video display monitor is

implemented using infrared sensor and transmitters that are located in the
bezel of the CRT screen.

2.OPERATING KEYBOARD: -

 Contain 147 touch keys that initiate actions. In this 85 are user
configurable function keys & 61 are standard operated function keys.

 Red and yellow color lamps (LED’s) are included on certain keys to
indicate important process and TDC3000 alarm systems.
 49

 User Configurable keys are 85 buttons on left side of operator

keyboard, that the user can define or configure to perform certain
functions, such as call up of certain critical frequently displays. Cross
screen displays or to activate particular action sequence.
 Standard Output function keys.61 keys on the right side of the
operator keyboard.
These are further divided into five groups:-

 Standard Process displays call &display control keys.

 Standard system displays call &system function keys.
 Standard process alarm management keys.
 Standard operator control keys.
 Standard numeric keys.

AC POWER ON/OFF AND ELECTRONICS MODULE

It is the part of the US, helps in AC &DC On/Off control, main electronic
processors, memory, and Local control network (LCN) interfaces and
other interfaces to connected peripherals and optional devices. Also, the
DC power supply, fan module and necessary interconnecting cable
assemblies for the US are also housed in the same unit.

4.ENGINEER KEY BOARD: -

These are of two types: -

 One is fixed in front of operator keyboard.

 2nd one is plugged into appropriate model of US.
 50

5.CARTRIDGE AND FLOPPY DISK DRIVE: -

 Used for random data storage. Both type of disk drives are compact,
easy to use, data storage and retrieval devices that accept removable
magnetic media.
 Disk drive: - 5.25-inch floppy diskette called floppy disk drive. A
floppy disk is a flexible; double sided, double density, enclosed in a
sealed jacket and has storage capacity of 1.2-MB.
 Cartridge disk drive accepts cartridge disk. The cartridge disk is
compact and high capacity disk rigidly-encased in plastic casing. A
cartridge drive has storage capacity of 20/40/150 MB.

6.DOT MATRIX PRINTER: -

Take B/w hard copy of various processes & it can print

 Logs Reports, Trends and Journals.

 Whatever is on the VDM screen, including Graphics?
 A record of alarms.

7.TREND PEN RERCORDER: -

 Record continuous trend of process values on the recorder paper.

 51

 Up to 8 trends pen can be driven by US.

 The trend pen recorders can be mounted on the universal station
within full view of the operation.

8.VIDEO COPIER: -

Video copier is an optional colour copier, which can be attached with a

US to take hard copy of current display on the VDM screen.

9.TRACK BALL: -

 Cursor pointing and target selection device

 Front mounted by the operator keyboard panel.

UNIVERSAL STATION PERSONALITY

To service man machine interface needs, following two software

functions termed, as personalities are available for Universal station
(U.S).
 52

 OPERATOR PERSNALITY is used for process operation from

US.
 ENGINEER PERSONALITY is used for TDC 3000 system
configuration for process control engineering and system
maintenance.

With the operating personality present in US, the operator

can: -

 Monitor and manipulate process parameter including startup and shut

down of plant units.
 View and manage the process and system alarm and message.
 Display and print continuous and discontinuous histories.
 Display and print process trend and averages.
 Display and print reports, logs, and journals.
 Copy data to/from floppy diskettes or cartridge.

 Monitor and change status of system equipment in the control room

and near the process.
 Load operating programs and data busses from a history module,
floppy diskettes, or cartridges.

Functions of Operator & Engineer personalities

in single software packed are also available which is termed as
UNIVERSAL PERSONALITY (U.P).
 53

SYSTEM AND PROCESS OPERATION FUNCTION:

 Monitoring and controlling continuous and discontinuous process

operation.
 Annunciating and handling alarms.
 Display and printing trends and logs, journals and reports.
 Monitoring and controlling system status and diagnostics.

PROCESS ENGINEERING FUNCTIONS: -

 Network configuration.
 Building process database.
 Building custom graphics.
 Designing reports.
 Preparing control language (CL) programs.

SYSTEM MAINTENANCE FUNCTIONS: -

 Diagnosing system problems.

 Displaying and printing information required during troubleshooting.
 54

LOADING OF UNIVERSAL STATION: -

Loading is the task of putting any one of the above mentioned personality
programs (OP/EP/UP) in the memory of US. After the loading a
personality, the US can serve as the man machine interface with
appropriate functions.

Loading of US is required on the following circumstances:

 On initial start up of US.

 Power resumption after power failure
 Change of personality program is in the US
 After resetting the malfunctioning US.
 55

The US is loaded with operator personality in following steps:

Step 1: A. check US powered ON
B. Adjust the contrast and brightness controls on
VDU panel to the prompt.
C. Check the prompt on the left top of the powered
ON universal station screen.
D. If the prompt is present then go to step 2
Else press RESET button on OKB and wait for
Prompt on US.
Step 2: A. Press LOAD key on OKB
B. Check on the US screen
If “N, 1,2,3,4,X?” displayed then go to step 3
Else contact the trainer.
Step 3: A. Type “N” and press ENTER key on OKB.
B. Check on the US screen;
If “OPR, ENG, X?” displayed then go to step 4
Else contact the trainer.
Step 4: A. Type “o” and press ENTER key on OKB.
B. Check on the US screen.
If “load in progress” displayed then go to step 5
Else contact the trainer.
Step 5: wait till “CONSOLE STATUS” display appears on the
Screen.
After the console status display appears on the US screen, US takes little
more time to settle down with the personality programs.
 56

UNIVERSAL STATION OPERATIONAL

SECURITY: -
Following operational security is implemented in universal station: -
 Checking each data entry for the right type. Universal station checks
each data entry from keyboard for the right type required for the
operation.
 Restricted access to TDC3000 functions and database like operating
parameters, configuration data and programs.

Following three access levels designed for the restricted access to

TDC3000 database are shown below in figure: -
 57

THREE ACCESS LEVELS ARE GIVEN BELOW: -

 Operator level
 Supervisor level
 Engineer level

Operator level: -permits the user to effectively monitor and manipulate

process parameters during normal operation, but doesn’t permit changes
to sensitive process parameters.

Supervisor level: -permits user to alter sensitive process parameter and

permit all the functions allowed at the operating level.

Engineer level: - permit user to access the entire data base to perform
process and system configuration functions and programs along with all
the functions allowed at the operate and supervisor level.
Level of access is determined by the keyboard, key-
switch position, access level position is marked on the key- switch panel.

Following key types enables key-switch positions:

 58

 Supervisor’s key
 Engineer’s key

SUPERVISOR’S KEY

It enables the access key switch to supervisor level.

ENGINEER’S KEY

It enables the access key switch to engineer level. This key can enable the
key switch to supervisor level also.
Without a key, the key switch remains enabled for the operator level
access. The access key can be removed from the key switch only by
bringing the key switch position back to the operator level.

One more special level of operational security can be configured called

view only.

VIEW ONLY

This level of access allows call up of various displays on US screen for

viewing, but does not permit any data entry.
 59

TDC OPERATOR CONSOLES

The group of universal stations is called an operator console.

Universal stations are combined to:

 Provide the required area and unit specific perception of the

process plant to the operator.

 Collect methodical responses from the operator for the process

plant area and unit specific operations.

Printers, floppy /cartridge drives and trend pen recorders attached to

respective us can be shared within an operator console.

An operator console can contain maximum ten US with or without

respective optional equipment.

US’s belonging to one console needs not to be located at the same place.

Alarm acknowledgement is console wide.

OPERATOR’S KEY BOARD

The operator’s keyboard with its key organization is shown below:

 60

It consists of user configurable function keys& standard operator

function keys.

DESCRIPTION OF STANDARD OPERATOR

FUNCTION KEYS.
 61

It is subdivided into five types of keys:

 Standard system displays call & system function keys.

 Standard process display call &display control keys.
 Standard process alarm management keys.
 Standard process operator control keys.
 Standard numeric key.

STANDARD SYSTEM DISPLAYS CALL &

SYSTEM FUNCTION KEYS.
 62

SYST STATS: System status key calls up the system status display on
US. The red lamp of the key blinks when there is an unacknowledged
system alarm and remains steady ON when all console alarms are
acknowledged but not removed.

CONS STATS: Console status key calls up the console status display
on US. The red lamp of the key blinks when there is an unacknowledged
console alarm and remains steady ON when all the console alarms are
acknowledged but not removed.

RECRD: Trend pen recorder key activates trend pen recording of

selected point on the trend pen recorder. The red lamp of the key
becomes ON while recording is in progress. Pressing the key again
terminates the recording and lamp switches OFF.
 63

FAST: Fast update key causes the update rate for process related
display information to increase to 2-second interval instead of the
standard update rate of once in 4 seconds. Red lamp of the key becomes
ON when fast update is selected. Pressing the key again terminates the
fast update and the lamp switches OFF.

CANCL PRINT: cancel print key is used to abort any currently

printing output on any printer in the console. When pressed, the prompt
asks the operator to enter the console related printer number. Cancel print
does not function across stations with different personalities.

PRINT DISP: print display key is used to print the current screen
display on the assigned printer.

PRINT TREND: print trend key activates trend printing for the
selected point. Trend for all points in an operating group can be printed
on the dot matrix printer.

SYST MENU: system menu display calls up the system menu display.

LOAD: load key is used to initiate the Universal Station for personality
loading. It works only when the US is not having any personality loaded
in its memory and is in POWER ON condition.
 64

STANDARD PROCESS DISPLAYS CALL &

DISPLAY CONTROL KEYS
These are the sixteen keys located at the left column of the standard
function keys. The diagram is shown below:
 65

GROUP: Group display key calls up the required group display on the
Universal station screen. A group number is required to be entered after
pressing of the key.

DETAIL: detailed display key calls up the detail display of required

point on the universal station screen. A point ID is required to be entered
after pressing this key.

UNIT TREND: unit trend key calls the unit trend display. A unit ID is
required to be entered after pressing this key.

TREND: trend key calls up the trend of the selected points on the group
display currently shown on the Universal station.
 66

BATCH: function of this key is deferred.

GOTO: go to key used to select a point on the group display. A point

number (1to8) is required to be entered after pressing this key.

SCHEM: Schematic key calls up a schematic display on the universal

screen. A schematic name is required to be entered after pressing this
key.

HELP: Help key calls up the pre configured display for showing
required help associated with current display on the universal station.

DISP SET: not implemented.

HOUR AVG: hourly averages key calls up the hourly average of

process values of the points from the group display, currently showing on
the universal station screen.

PRIOR DISP: prior display key calls up the display that showing
immediately before the current display on the universal station screen.

ASSOC DISP: associated display key calls up the configured display

associated with the current display on the universal station screen.
 67

DISP BACK: display back key calls up next lower numbered display
within the same type of display currently showing on the universal
station screen.

DISP FWD: display forward key calls up next higher numbered

display within the same type of display currently showing on the
universal station screen.

PAGE BACK: page back key calls up the next lower numbered page
of a multi page display currently showing on the universal station screen.

PAGE FWD: page forward key calls up the next higher numbered
page of a multi page display currently showing on the universal station
screen.
 68

PROCESS ALARM MANAGEMENT KEYS:

There are the middle eight keys in lower rows of the standard function
keys. These keys are used for alarm management. Diagram showing
these keys is shown below:
 69

ACK: alarm acknowledges key is used to acknowledge the process and

system alarms for the console. Details of use of this key will be covered
in alarm management.

SIL: silence key is used to silence audible alarms in the console.

Pressing this key dose not ACKNOWLEDGE the alarms.

MSG SUMM: message summary key calls up the message summary

display on the universal station screen. The red lamp of the key blinks on
the presence of messages that require operator acknowledgement.
Steadily ON lamp indicates the presences of a message acknowledged
but requires operator confirmation/cancellation.

ALM SUMM: alarm summary key calls up the area alarm summary
display on the universal station screen. The red and yellow lamps of the
key represent different alarm priorities. On the occurrence of the process
alarm the respective priority lamp blinks for the operator attention &
requires operator acknowledgement.

ALM ANNC: alarm annunciator key calls up the alarm annunciator

display on the universal station screen.
 70

MSG CONFM: message confirmation key is used to confirm a

message currently displayed on the message summary display.

MSG CLEAR: message clear key is used to clear messages that have
been acknowledged and confirmed on the message summary display.

UNIT ALM SUMM: unit alarm summary key calls up the unit alarm
summary display. A unit ID is required to be entered after pressing this
key.
 71

STANDARD PROCESS OPERATOR CONTROL

KEYS

These are the right side fifteen keys of the standard operator function
keys. These keys are used to change the process parameter currently
selected on the universal station display.
 72

MAN: manual mode key used to change the operating mode of the
selected point to manual mode of operation.

AUTO: auto mode key used to change the operating mode of the
selected point to automatic mode of operation.

NORM: normal mode key used to change the operating mode of the
selected point to normally configured mode for operation.

SP: set point key used to initiate set point value changes of a point. A
value is required to be entered either by numeric keys or by raise/lower
keys after pressing this key.

OUT: output key is used to initiate analog or digital output value

changes of respective points. A value is required to be entered either by
numeric keys or by raise/lower keys after pressing this key.

SLOW RAISE: slow raise or digital state (ON) change key.

SLOW LOWER: slow lower or digital state (OFF) change key.

FAST RAISE/FAST LOWER KEY: fast raise /lower keys are

used to fast increment/decrement the selected value of the point. When
the key is pressed fast increment /decrement in value results every 2/3 of
 73

a second by 2,3,5,10%of the full scale depending on the system

configuration.

CLR ENTRY: clear entry key clears an entry made before the ENTER
key is pressed.

SELECT: select key is used to select an item at the current cursor

position.

TAB KEYS: tab keys are used to position the cursor on the universal
station screen. On pressing these keys cursor can be moved horizontally
left/right or vertically up/down. If the key is held down the cursor
movement is continuous.

STANDARD NUMERIC KEYS

These are the 13 keys centrally located on the standard operator function
keys & are used to enter numeric values. The numeric keys are shown
below:
 74

The ENTER key is pressed to complete the data (numeric as well as well
alphabetic keying) entry.

TOTAL PLANT SOLUTION

The total plant solution TPS system consists of a local control network&
at least one process network. There are three possible process networks,
 75

the Data hiway, the Universal Control Network (UCN)& the

programmable logic controller (PLC) subsystem.
Each of the process networks has an interface (called a
“gateway”) that allows it to communicate with the Local Control
Network, which is where TPS work station are located. The gateway for
universal control network interface is called the network interface module
(NIM)& the gateway for the Programmable Logic Controller subsystem
is called the PLCG.
The process network (Data Hiway, Universal Control
Network, Or Programmable Logic Controller Subsystem) transmit
process data from/to process connected devices such as controllers &
data aquisation devices (such as temperature, flow & level) through their
gateway to local control network. This makes it possible to see what is
happening at the process without leaving the workstation, on the local
control network. TPS workstation can be Universal Station Or Global
Universal Station (GUS).
Combination of these devices is also possible.

TOTAL PLANT SOLUTION SYSTEM OVERVIEW

 76

THE MAJOR COMPONENTS OF TPS

SYSTEM ARE: -

UNIVERSAL CONTROL NETWORK (UCN)

The communication channel for the advanced process manager is called

universal control network (UCN) .The UCN is the platform for
processors I/O connections to the TDC 3000.
 77

It is high speed, high accuracy & high security process

control network. It is peer to peer communication capability allow for
easy sharing of process data making it convenient to implement
sophisticated control schemes.
The UCN features a 5-mega bit per second Carrier Band
Communication System with a token bus network. It is designed to be
compatible with IEEE and ISO standard. UCN communications are
consistent with the growth and direct of evolving international standards,
appropriate honey well extension for secure process applications.
The UCN uses redundant coaxial cables and can support
up to 32 redundant devices. The UCN support peer-to-peer
communication for sharing data between devices on this network &
allowing greater coordination of control strategies. This feature enables
sharing information among advanced process manager, process manager,
and logic manager on the network (UCN process connecting device) and
local control network modules such as history module, application
module and plant network module, thus offering tremendous power and
flexibility in implementing advance coordinated control strategies.
The UCN is connected to single or multiple LCN’s using
network interface module (NIM). Up to 20 UCN and data Hiway can be
connected to the same LCN. At LCN all of the process data from this
process network is available for the standard TDC3000 operate, control
history and management functions. For example, both UCN & data
Hiway based information can be combined into the sane group and
custom the graphic displays. Or accessed for history or more advanced
control functions as needed.
 78

FUNCTIONAL DESDCRIPTION: -
 The universal control network provide a power communications
platform for efficient secure real time process communication .as a
leader in a process control, HONEYWELL has extensive, expensive
with real time process network

LOCAL CONTROL NETWORK (LCN)

The TPS system consists of many different hardware modules. These

modules are dependent on one another and require efficient and reliable
communication paths between them. LCN is basically used for man
machine interface.

LCN DESCRIPTION

 Each of these nodes has a separate address and is configured to this

address through the use of these jumper plugs (pinning) at the time of
installation.
 Each of the Hardware Module (nodes) attached to the LCN have
some common functionality, consisting of an LCN interface
mechanism, a processor and memory. This common functionality is
often referred to as the “kernel”.
 An LCN node takes from when distinct hardware is added to its
Kernel or common logic. A specific purpose board such as diskette
controller, video generator, special hardware board, etc. bring a
personality with it to the LCN hardware module. In addition, the node
is loaded with a unique software package, written specially for that
 79

application. The combination of common hardware, special hardware

and specially designed software combine to form the node’s
specialized personality.
 The LCN network consists of two redundant coax cables that run
continuously from node to node (in a bus topology). Each cable is
connected to each node’s LCN interface circuits with a T-connector.
One cable is marked CABLE A and the other is marked CABLE B.
 Both redundant cables are connected to each node. Each node has
specific connection for both A and B cable and they must not be
crossed. Terminators are used on the ends of both cable A and B. The
over all length of each LCN cable segment should be kept nearly
equal to its redundant companion with a maximum length of 300
meters and maximum load of 40 physical connections for each LCN
cable. Fiber optics can be used to exceed some limitations.

LCN COMMUNICATION PROTOCOL

The LCN communication Protocol is broadcast type of local area

network. Modules “talk”(broadcast) on both the A and B cables
simultaneously, but they “listen”(receive) on only one cable. All LCN
modules hear all transmission but, depending on message destination and
type, only some modules process certain messages.

A token passing algorithm is used so that up to 64 modules can share

access to the LCN. The communication master node defines (to other
 80

nodes) which cable should be used for listening. The communication

master node is the Universal Station (US) with the lowest LCN address;
it periodically issues an instruction to switch cables. This ensures that
both cables remain functional.
If any node experiences difficulty in receiving data on
a specific cable, it switches cables and informs the communication
master. The communication master then informs all the other nodes to
switch to the good cable and dispatches a message to the system
maintenance control center (SMCC) requesting maintenance on the
suspect cable. This allows operation to continue while the faulty cable is
being repaired.

TOKEN PASSING

Following figures illustrate a sample LCN arrangement where token

passing has been established between several nodes. The number inside
the “ring” in the figure represents the node address of the modules on an
LCN. Remember, the “ring” is imaginary; the physical nodes are really in
a “string” with the actual node addresses arranged in random order.
LCN OVERVIEW
 81

TOKEN PASSING SYSTEM

 82

AVANCED PROCESS MANAGER (APM)

It is an advanced data acquisition and control device used for regulatory,

logic and sequence control operation required for continuous or batch
applications. It consists of a redundant advanced process manager
module (APMM) and maximum 40 input out put processors (IOP).
 83

The advanced process manager (APM) is Honeywell premier

TDC 3000 data acquisition and control device for industrial control
applications.
Like the process manager (PM), the advanced process
manager new technology platform offers a range of capabilities that best
meet today and tomorrow’s process requirements. The ASPM offer
highly flexible I/O functions for both data monitoring and control. Power
control functions, including regularity, logic and sequencing control for
provided for continuous, batch or hybrid applications. An optical toolbox
of functions that can be configured and programmed meets the needs of
data acquisition and advance control requirements in a highly secure and
performance intensive manner. Of course, Amp’s capabilities include
peer-to-peer communication and compatibility with industry standard
protocols. As seen in the figure the advanced process manager is a fully
integrated member of the TDC 3000 family.
ACCORDINGLY APM IS CAPABLE OF: -

 Performing data acquisition and control functions, including

regularity, logic and sequential control functions, as well as per to
peer communications with other universal control network-reside4nt
devices.
 Providing bi-directional communication to modbus and ALLEN –
BRADLEY COMPATIBLE subsystems through a serial interface.
 Fully communicating with operators and engineers at universal
station and universal workstations. Procedures and displays are
 84

identical or similar to those used with other TDC3000 controllers.

Plant personnel may already be familiar with them.
 Supporting higher-level control strategies available on the Local
Control Network through the application module and host computer.

ADVANCED FEATURES: -

As described above, the Advanced Process Manager (APM) has the same
functionality that of the process manager (PM) plus:
 Digital input sequence of events (DISOE) processing.
 Device control points.
 Array point for CL programs.
 Foreign device (serial) interface capability.
 Larger memory (over four times larger than the PM).
 String variables.
 Time variable.

FUNCTIONAL DESCRIPTION: -

The advanced process manager is designed to provide flexible and

powerful process scanning and control capabilities .To do this, it uses
advanced multiprocessor architecture with separate microprocessor
dedicated to perform specific tasks. The APM consist of the advanced
process manager module (APMM) and the I/O subsystem.
 85

The advanced process manger module consists of an advanced

communication processor and modem, advanced I/O link interface
processor and advanced control processor, a redundant APMM can be
optionally provided.
The advanced communication processor is optimized to
provide high performance network communications. Handling such
functions as network data access and peer-to-peer communication, it also
supports high accuracy time samps.

NETWORK INTERFACE MODULE (NIM)

The network interface module (NIM) provides the link between the
LOCAL CONTROL NETWORK and the UNIVERSAL CONTROL
NETWORK. Accordingly it makes the transition from the transmission
technique and protocol of the local control network to the transmission
technique and protocol of the universal control network.
The NIM provides the LCN module access to data from
UCN resident device. It support program and database loads to the
advanced process manager and forward alarms and message from the
network device to the LCN. The NIM is also available in the redundant
configuration to provide automatic continued operation in the event of
primary failure.
 86

LCN time and UCN time are synchronized by the NIM. The
NIM broadcast LCN time over the UCN. The APM uses it for all alarms
(or events) time stampings.

LOGIC MANAGER (LM)

The logic manager (LM) is a process-connected device that resides on the

TDC 3000 Universal Control Network as a peer to the process manager.
The LM consists of a standard Honeywell Logic Controller (LC) that
contains a two-slot option module known as Logic Manager Module
(LMM) and is mounted in one or more standard TDC3000 cabinets.

The main features of Logic manager are:

1. Direct peer-to-peer communication with other UCN devices.

2. Communication with operator, engineer and maintenance
technicians at the universal station.
3. Support of higher-level control strategies through communication
with AM.
4. Database saving and restoration from the HM.
 87

The logic manager (LM) is implemented for the application requiring fast
logic program execution, extensive digital or interlock logic and ease of
ladder programming.

LOGIC MANAGER OVERVIEW: -

 88

As shown in the figure the Honeywell 620 Logic Controller uses two
basic types of racks. These are: -

 Processor Rack
 I/O Rack

Logic Manger (LM) consists of a Honeywell 620-35 PLC processor rack

with Logic Manager Module (LMM), Parallel and Serial I/O racks and an
MS-DOS Loader Terminal. The LMM serves as an interface between the
620-35 processor racks and the UCN. It converts the PLC data into UCN
format and vice versa.

The MS-DOS loader terminal is an IBM compatible PC, which serves as

a man machine interface and is used for graphic display and ladder
programming. The communication between the PC and processor take
place using an interface board and a serial cabinet shipped with 620-35
PLC.
The LM processor subsystem consists of a standard Honeywell
620-35 processors rack plus a two slot optional module known as Logic
Manger Module (LMM), used for UCN connectivity. The subsystem
 89

hardware includes the chassis, back plane, and front plates. The processor
module is vertically positioned in the racks with the component side
towards left. Back plane connector is offset to prevent inserting a module
upside down. The rack fits into an 8” NEMA 12 enclosure or 19”
instrumentation rack with 14 slots to insert modules.
The LM processor rack has 14 slots from A to N where
different optional or standard modules could be inserted.

THE DIFFERENT LM PROCESSOR RACKS ARE:

 Processor Module (PM)-slot H

 System control Module (SCM)-slot G
 Register Module (RM)-slot F
 Memory Module –slot E
 Input/output Control Module (IOCM)-slot I
 Power Supply Module (PSM)-slot J&K
 Parallel link Drive Module (PLDM)-slot N
 Serial Link Module (SLM)-slot L & M
 Logic Manger Module (LMM)-slot A &B
 Redundancy Control Module (RCM)-slot C
 Addition 8Kword Memory Module
 90

REDUNDANCY SYSTEM

The LM redundant control system consists of two identical configured

processors, each containing a redundancy control module (RCM). One
processor is LEAD processor and the other is the BACKUP processor.
The system permit sharing of data between the two redundant processor
by transferring I/O status cable, register table and system status table. In
the event of failure the control of I/O is transferred from the LEAD
processor to the back up processor.

REDUNDANCY CONTROL MODULE

It is a primary component of a LM redundancy control system. It is

responsible for:

 Transferring I/O status table, Data register table and system status
table information from the LEAD to BACKUP processor.
 Monitoring the status of other RCM and its own host processor.
 Switching the control from LEAD to BACKUP processor in the
event of hardware failure of LEAD processor or the user request.

SERIAL LINK SELECTOR

This is general purpose switching device, which may be used, for

connecting MS-DOS loader terminal to the two processors.
 91

REDUNDANT SIOM

In LM redundant system this module is used instead of normal SIOM. It

has two ports to which the serial I/O cables coming from the two
processors are connected. It also has the RUN/FREEZE toggle switch.
When the switch is in:
 RUN position normal communication between SLM and serial
I/O track is permitted
 FREEZE position all real I/O is freezing and communication
between SLM and serial I/O rack is halted.

OVERVIEW OF REDUNDANCY SYSTEM

 92

OPERATION OF REDUNDANCY CONTROL SYSTEM

Consider a LM redundancy processor system with two processor viz. A

and B. suppose initially processor A is in lead status and processor B is in
the backup status. In the two processor same ladder program is stored and
before every program scan processor A updates the I/O status and
register data in the processor B. thus even though both the processor
 93

share the same program and data but actual controlling is done by
processor A. a backup processor can be requested to take over the control
of the system either automatically (when lead processor fails) or
manually (by pressing the lead request switch). When the RCM of the
back up processor (in above case it is processor B) grants the lead request
it take following action:

 It informs the RCM of processor A that it is taking over the control of

the system.
 It commands PBS to transfer all PBS to transfer all parallel I/O
operation to it instead of processor A.
 It commands SLS to transfer all serial I/O operation to it instead of
processor A.
 Turns on the LEAD status LED on the front plate.

The RCM of the processor A, in turn relinquishes the control of serial

and parallel I/O racks and turns off the LEAD status LED. Now the
processor B act as a lead processor and processor A act as a backup
processor in the PLC system. Normally the manually lead request is done
while updating the control program. Thus there is no disturbance in the
process operation while a program upgrading is being done. After the
fault is recovered or when a new program is down loaded the user can
again put processor A in lead position using above method. A step by
step method of online program down loading making use of redundancy
is as follows:
 94

 Consider above LM redundant processor system with two processor

viz. A and B with initially, say processor A in lead status and processor
in backup status and we want to download a new program in the system.
Ensure that both the processors are online. That is they are either in RUN
or RUN/PROG mode.
 Press led request switch on the RCM of processor B and wait till the
LEAD status indicator becomes on. Now processor B executes the
control program and the program A is backup status.

 Put processor A in PROGRAM mode using the mode key switch on

its PLDM.
 Connect the MS-DOS loader terminal to processor A and download
the modified ladder program to it.
 Put processor A in RUN or RUN/PROG mode using the mode switch
key on its PLDM.
 Press led request switch on the RCM of the processor A and wait till
the lead status indicator becomes on. Now the new control program start
execution and the processor B goes in backup state.
 If the new program is not working properly then repeat steps 2 to 6.
 Put processor B in PROGRAM mode so that the new program gets
downloaded in the processor B from A via data cable. Wait till PORT
ACTV indicator on the both RCMs is on and after that put processor B
back in RUN or RUN/ROG mode.
 95

INDUSTRIAL TRAINING
REPORT
Doing at
GURU HARGOBIND THERMAL PLANT
LEHRA MOHABATT
DISTT. BATHINDA
In
The Partial Fulfillment For The Requirement Of
Award of DEGREE
In
Electronics&communication

SUBMITTED TO:
H.O.D.
ELECTRONICS&COMMUNICATION
S.U.S.C.E.T.TANGORI
MOHALI

SUBMITTED BY:
INDER VERSHA
E.C.E-FINAL YEAR
 96

ROLL NO. 9901744

ACKNOWLEDGEMENT
Industrial training is the effort to provide linkage between the student and Industry in order to develop the
awareness of industrial approach for saving the problem based on broad understanding of tools, modes of
operation of Industrial Organization.
With the deep sense of gratitude, I express my sincere thanks to PSEB, Patiala,
who permitted me to take up training at the Organization. I wish to extend my thanks to Er. M.S.Thind
(S.E./C&I), Er.A.K.Chugh (Add. S.E.), Er.K.K.Jain (Add.S.E)&Er. Chhabra (Add.S.E) for their considerable
help to join the training in different sections of C&I department. I humbly express my cordial thanks to Mr.
Parveen Jain (A.E), Mr. AjitPal Singh (A.E), Mr. Dhiraj Bansal (A.E) and Mr. S.k.Sharma (A.E) for their extra
pain to see me through my problems. They have been always a source of encouragement and inspiration for
me. Under their efficient guidance, I had no problem in acquiring and getting various jobs done. I am always
thankful to staff of industry for their kind cooperation and help, which made me training a success.
I feelthat information gathered by me during this training will surely help me a lot
in coming future.

ABSTRACT
 97

My industrial training of six months of seventh semester of

B.Tech. Electronics&communication
As planned by Punjab technical university is organized in the
Thermal Power Generation Plant at Lehra Mohabbat Distt.
Bathinda.
My training of six months is divided in three
departments of control&instrumentation each of two months.
This report contains overall plant circuit &department wise
description.

INDERVERSHA
I
 98

CONTENTS
 99

1. INTRODUCTION
2. WORKING OF THERMAL PLANT
3. SYSTEM DESCRIPTION
4. TDC 3000
5. UNIVERSAL STATION
6. TOTAL PLANT SOLUTION
7. REDUNDANCY SYSTEM

INTRODUCTION

 BRIEF HISTORY OF PLANT

 PROFILE OF PLANT
 POWER DISTRIBUTION
 RAW METERIAL &THEIR SOURCES
 BASICS OF THERMAL PLANT
 100

 RANKINE CYCLE ON TEMPRATURE ENTROPY

DIAGRAM
 PROCESS OF POWER GENERATION
 PLANT OVERVIEW
 BLOCKS DISCRIPTION
 VARIOUS CYCLES INVOLVED IN POWER
GENERATION
 101

SYSTEM DISCRIPTION

 COAL HANDLINGSYSTEM
 FUEL OIL SYSTEM
 ASH HANDLING SYSTEM
 D.M.PLANT
 EMERGENCY POWER SUPPLY SYSTEM
 CONTROL&INSTRUMENTATION SYSTEM
 DATA ACQUISATION SYSTEM
 POWER SUPPLY DISTRIBUTION SYSTEM
 102

TDC 3000 SYSTEM

 AREA UNIT POINT CONCEPT

 DISTRIBUTED CONTROL SYSTEM
 FUNTIONS DISTRIBUTED AROUND DCS
 BENEFITS OF DCS
 TDC ARCHITECTURE
 TDC 3000 PROCESS OPERATIONS
 103

UNIVERSAL STATION

 DIFFERENT PERIPHERIAL CONNECTED TO U.S.

 UNIVERSAL STATION PERSONALITY
 LOADING OF U.S
 U.S OPERATIONAL SECURITY
 TDC OPERATOR CONSOLES
 OPERATOR’S KEYBOARD
 DESCRIPTION OF STANDARD OPERATION FUNTION
KEYS
 104

TOTAL PLANT SOLUTION

1. OVERVIEW OF TPS
2. MAJOR COMPONENTS OF TPS
 LOCAL CONTROL NETWORK (LCN)
 DESCRIPTION
 LCN COMMUNICATION PROTOCOL
 TOKEN PASSING
 OVERVIEW OF LCN
 ADVANCE PROCESS MANAGER (APM)
 CAPABILITIES OF APM
 ADVANCE FEATURES
 FUNCTIONAL DESCRIPTION
 NETWORK INTERFACE MODULE (NIM)
 105

 LOGIC MANAGER (LM)

 OVERVIEW OF LM
 DIFFERENT LM PROCESSOR RACKS

REDUNDANCY SYSTEM

 REDUNDANCY CONTROL MODULE

 SERIAL LINK SELECTOR
 REDUNDANT SIOM
 OVERVIEW OF REDUNDANCY SYSTEM
 OPERATION OF REDUNDANCY CONTROL SYSTEM