The slides gives a brief introduction of operation and control of a Thermal power plant. Posting from my personal Experience during my internship at Rajasthan Spinning and Weaving Mils (RSWM) Ltd. It gives a brief introduction of the installed 46 MW Generation system used by company along with the overall process. The aim is to help undergraduate students to learn about the overall introduction to Power Plant engineering.

1. Swapnil Trivedi
Origination study of RSWM Thermal Power Plant
An Industrial Internship Report
In partial fulfillment for the award of the degree of
Bachelor in Technology
Electrical and Electronics Engineering

2. RSWM is a professionally managed, progressive and growth oriented company with business
interests in Yarn, Fabrics, Garments and Denim. It is one of the largest producers and exporters of
polyester viscose blended yarn in the country. The company operates around 3,60,000 spindles
and produces 1,00,000 MT of yarn per year
RSWM aims being self sustaining thus is having its own three private thermal Power plants spread across
parts of Rajasthan.

3. RSWM
Mordi Power Generation Site
THE RSWM LTD POWER PLANT HAS THE CAPACITY TO GENERATE A TOTAL OF 46 MW OF
ELECTRICITY. AS THERMAL POWER PLANT IS ONE IN WHICH PRIME MOVER IS STEAM DRIVEN,
RSWM POWER PLANT HAS 2 IDENTICAL BOILERS EACH HAVING A CAPACITY OF 105 TPH OF
STEAM FOR GENERATING 23 MW EACH. SOURCE OF RAW WATER FOR STEAM PRODUCTION IS
MAHI RIVER AND COAL REQUIRED FOR HEATING OF WATER IS IMPORTED FROM DIFFERENT
MINES OF INDIA (CHHATTISGARH) AS WELL AS FROM ABROAD (INDONESIA). ALMOST HALF OF
THE POWER GENERATED IS USED AS HOME LOAD AND REMAINING IS EXCHANGED WITH
GOVERNMENT. RSWM POWER PLANT IS SUBDIVIDED INTO VARIOUS PARTS AND ARE NAMED
ACCORDING TO THE WORK THEY PERFORM LIKE ASH HANDLING PLANT WHICH DEALS WITH
THE ASH PRODUCED ON BURNING OF COAL. .

4. SOURCES
COAL
•Anthracite and Bituminous.
•Between 10000 KJ/Kg to 25000 KJ/kg.
• A blend is made having a HCV of approx. 3300
Kcal/kg.
•2 identical boilers each having a capacity of 105
TPH
WATER
• The main source of steam is Water.
• The plant takes a majority of its water
supply from the backwaters of Mahi Dam.
• A pump house in “chandu ji ka Gada”
makes sure that water supply is maintained
• Almost 30-35% of water is recycled for the
Denim unit.

5. TASK ASSIGNED
o I joined RSWM’s Mordi Thermal Power Plant on 13 May 2019.
o I joined the Control and Instrumentation department under the guidance of
Mr.Omprakash Gautam(HOD).
Project Assigned:
• Study about flow of Process.
• Study of Human safety and Equipment safety.
•Mentor assigned Mr. Sahil Nanavaty(Senior Assistant Engineer)

6. NAME
1 CHAPTER 1- COAL HANDLING PLANT
2 CHAPTER 2-BOILER
3 CHAPTER 3-DM PLANT
4 CHAPTER 4-ASH HANDLING PLANT
5 CHAPTER 5- TURBINE FLOOR
6 CHAPTER 6-GENERATOR AND EXCITORS
7 CHAPTER 7-SWITCHYARD AND TRANSMISSION
8 CHAPTER 8-CONTROL AND MONITORING
9 CONCLUSION
Table of context

7. COAL HANDLING PLANT
Important Parts of CHP:
1. Belt Feeders
2. Vibrating Feeder
3. Belt Conveyor
4. Magnetic Separators
5. Crushers
6. Screen
7. Dust Extractor
Safety Mechanisms Used:
1. 150x150 mesh
2.In line magnetic Separator
Belt and Human Safety devices:
1.Zero Speed Sensor
2.Belt Sway Switch
3.Pull cord Switch
4.Belt Monitoring System(BMS)

9. BC-1 lifting coal150x150 Hopper sieve BC-1 connecting BC-2
3 Phase Induction motor
for Belt conveyor
Vibrating Screen Belt Sway Switch Dust Extractor system

10. BOILER
Important Parts of Boiler:
1. ID fan
2. FD fan
3. PA fan
4. Air Pre Heater
5. Drain Chain Feeder
6. Super Heater
7. Economizer
Safety and monitoring:
1. O2 analyzers in boiler and APH ensures
sufficient amount of oxygen level.
2. ID,FD and PA fan are interconnected via
closed loop mechanism which helps in
maintaining a constant pressure for the
supply routes.
3. RTD’s and Thermocouples for Temperature
measurement.
4. DPT and i2P monitoring devices.

12. BC-2 connecting to
Daybin
J type Thermocouple
Used in compressor
Hot pipelines used for
extraction of impurities
from Boiler bed
Ash storage Bins Hopper
Hopper to Belt
Conveyor 4
EconomizerAir Pre HeaterInduced Draft FanForce Draft Fan

13. DM PLANT
In the operation of a steam power plant, there are various types of water requirements
depending upon the location and purpose for which it is used, and they all differ in water
chemistry i.e. pH, turbidity, hardness, TSS, TDS etc. Demineralized water is crucial type of water
as it is used for steam generation in the boiler. Raw water contains organic matter, inorganic
salts, bacteria which need to be removed before being purified. Steps involved in this process
are:
1. Chlorination
2. Stilling chamber
3. High Rate Solid Content Calorifier (HRSCC)
4. Dual Media Filter (DMF)
5. Ultrafiltration system (UF System)
6. Strong Acid Cation
7. Degasser

15. ASH HANDLING PLANT
In Thermal Power Plant’s coal is generally used as fuel and hence the ash is produced as the
byproduct of Combustion. Ash is generated in power plant in big amount and hence a system is
required to handle ash for its proper utilization or disposal. If ash is not removed periodically,
then there is a good possibility of backfiring of boiler i.e. there is possibility of boiler explosion.
Ash handling plant mainly consists of APH, Electro-static precipitator, ID fan, chimney and Silo.

17. Air compressor
SuperHeater
ACC
Air Cooled Condenser

18. Turbine and Water cycle
Important Parts:
1. Condenser storage tank
2. Condensate extraction tank
3. Ejector
4. Gland Steam Condenser
5. Drain cooler
6. Low pressure heater
7. Deaerator
8. Boiler feed pump
9. High pressure heater
10. Hotwell
11. Air cooled condenser
Speed –7500-7000RPM
Pressure – 66kg/
Temperature – 500-540
Gearbox ratio: 1:5 +-0.25
Speed Switches and Vibration Monitors are used on
Turbines and Generators to monitor critical speed and
vibration levels, and guard against slowdown or stoppage
that can result in costly process downtime, machine
damage, and material waste. Ratemeters and
Tachometers are commonly used in this type of application
to display the RPM of the pump.

20. Generating System
Consist of :
•Alternator
•Governor
•Excitator
In RSWM plant, DC (Brushless) excitation
is used to generate electricity. After turbine
starts to rotate at around 7700 rpm, the
alternator coupled with it runs at 1500 rpm
(speed is decreased by gear system). AVR
Safety of the system:
1. Over speed of engine.
2. Low voltage.
3. High water temperature.
4. Low lube oil pressure.
5. Winding temperature.
6. Low Water of cooling tower.

22. SWITCHYARD
Important Parts:
1. Isolator
2. Lightening Arrestor
3. Circuit Breaker
4. Current Transformer
5. Potential Transformer
6. Power Transformer

24. Figure : Power Transformer
TYPE OF COOLIN G
ONON ON—cr4OFF
KVA 40000 50000
VOLTAGE(AT NO
LOAD)
HV 132000
LV 11000
AMPERE HV 175 218.7
LV 2099.4 2624.3
Rating of Power Transformer:

25. Isolators Lightening Arrester Potential Transformer

26. Control & Instrumentation
Main objectives of control and instrumentation in Thermal Power Plant are:
1. Efficient Operation of the plant.
2. Economic Operation of the plant.
Safe operation of the plant.
This entire task is often taken up by control & instrumentation or simply instrumentation system
which has following functions: -
a) Measurement b) Control
c) Operation d) Monitoring
For a Plant Measurement system needs to be:
1. Very accurate
2. Reliable

27. WHAT TO MEASURE HOW TO
MEASURE?
Accuracy: Closeness with which an
instrument reading approaches the true value
of the variable being measured.
Precision: A measure of reproducibility of the
measurements; i.e. given a fixed value of a
variable, precision is a measure of the degree
which successive measurements differ from
one another.
Sensitivity: The ratio of output signal or
response of the instrument to a change of
input or measured variable.
Resolution: The smallest change in measured
value to which the instrument will respond.
Error: Deviation from the true value of the
measured variable
Quantities to Be Measured:
Pressure
Temperature
Flow
Level
Expansion/ Contraction
Analysis of:
Water
Steam
Flue Gases And Others

28. Parameters Measuring points Sensors used
1) pressure 1) Turbine
2) Boiler
3) Other heat and steam lines
1) DPT (Differential pressure transmitter)
2) Bell Gauge
3) Pressure Gauge
4) Bourdon Tube
1) Temperature 1) APH
2) Furnace
3) Water at economizer
4) Generators and motor temperature
5) Steam at superheater inlet and outlet
1) Thermocouple (k type) for high range up to 1200c
2) RTD for small ranges typically within 100c
PT100
1) Vibration 1) Turbine shaft
2) Generator
3) Gear box
4) Bearing shells
1) Capacitive vibration sensor
2) Mass spring vibrator
1) Level 4) Boiler Drum
5) Condensate Tank
6) DM storage tank
7) Water line
1) Differential Pressure Methods and other
transmitters.
1) Expansion Turbine shaft
Turbine Casing
Furnace tubes
1) Relative displacement transmitters
1) Analysis
Water
Flue Gases
1) boiler inlet
2) DM storage tank
3) Raw water tank
Conductive cell with meter
O2 analyzer economizer to air heater.(zirconia cell)
Dust conc.- optical analyzer

29. VARIABLE FREQUENCY DRIVE
A variable frequency drive (VFD) is an electrical variable speed drive that is added to motor-
driven systems to help save energy. Motor-driven systems are designed to handle peak loads.
When these operating systems work for extended periods of time at a reduced load, it wastes
energy. Adding a VFD allows you to adjust the motor-speed capability and match it with motor-
output load. This is how it saves energy. The motor-driven system is connected to the VFD and
allows us to have speed control by changing the frequency of the motor-supply voltage.
Advantages:
Increased productivity & product quality
Less wear & mechanical stress
Noise reduction along energy savings of 30%
Power factor correction close to 1

30. APPLICATION AND HANDLING

31. Used with:
Induced draft fans
Forced Draft fans
ACC fans
Boiler feed Pump

33. DISTRIBUTED CONTROL SYSTEM
A distributed control system (DCS) is a
computerized control system for a process or
plant usually with a large number of control
loops, in which autonomous controllers are
distributed throughout the system, but there is
central operator supervisory control. This is in
contrast to systems that use centralized
controllers; either discrete controllers located
at a central control room or within a central
computer. The DCS concept increases
reliability and reduces installation costs by
localizing control functions near the process
plant, with remote monitoring and
supervision.

34. Basic Elements of Distributed Control System
CPU
Analog Input Module
Digital Input Module
Analog Output Module
Digital Output Module
Communication System
Human Interface system (HIS)
“Today the functionality of SCADA and DCS
systems are very similar, but DCS tends to be
used on large continuous process plants where
high reliability and security is important, and
the control room is not geographically
remote.”

35. THANK YOU
Contact: Swapniltrivedi1456@gmail.com