Summer TrainingA Presentation On

“HINDUSTHAN ZINC LIMITED ” 80 MW (CPP)

 

Contents :1. Introduction2. Captive Power Plant3. Overview4. Thermal power plant5. Basic elements of Thermal Power Plant6. Distributed control system (DCS)

INTRODUCTIONLOCATIONHindustan Zinc Ltd,CaptivePower Plant is a certified unit of ISO, Quality management system, Environmental management system and Occupational, health and safety It is the only integrated Zinc-Lead producer in India & aims at becoming global leader in Zinc production. Also it has proven track record from last 40 years in mining &smelting

Hindustan Zinc Limited is a power intensive industry, the manufacturers of Non ferrous metals. To compete with worldwide market and establish itself, the Zawar Captive Power Plant (CPP) has been established along with CPP in Chanderiya and Debari.

CAPTIVE POWER PLANTCaptive Power Plant is a generating unit(s) which produces power for captive consumption (minimum 51%) of its owners.CPP is efficiency oriented, eco-friendly and eco-nurturing initiative towards environmental protection and continued commitment to sustainable power development in India.

OVERVIEW(1X80 MW unit)

BOILERTHERMALSTATIONCAPACITY 100% coal OR 100% dieselFUEL-COAL-SOURCE Imported coal from South Africa

and Indonesia. Indian coal from Navlakhiand Mundra Port.

TRANSPORTATIONBy truckCONSUMPTION7680 TPDCOOLING WATER SOURCETididamREQUIREMENT 5000m3

START UP POWER 16.5MVA@ 132KV

ASH DISPOSAL Dry ash disposal systemCHIMENY RCC multifluechimney With

steel flue 175m highHEAT RATE2670 Kcal/KWhHP/LP BYPASS 60% of MCR CAPACITY

Thermal Power PlantA Thermal Power Station comprises all of the

equipment and a subsystem required to produce electricity by using a steam generating boiler fired with fuels to drive an electrical generator.

This involves the generation of steam in the boiler by burning coal.

The steam in turn drives the turbine. The Turbo Generator coupled with the turbine produces electricity which is stepped up with the help of transformers and is fed into grid station through transmission lines.

The rm a l Powe r P l a n t s c on t r i bu t e m ax i m um t o t he ge ne r a t i on o f Powe r f o r a ny c oun t r y.

I n t he rm a l g en e r a t i ng s t a t i ons c oa l , o i l , n a t u r a l ga s , e t c a r e em p l oye d a s p r i m a ry so u rc e s o f e ne rgy.

Diagram of a typical coal-fired thermal power station

Basic Idea of ElectricityGeneration

Coal is unloaded from truck at Coal Yard

Coal is crushed to finer pieces of order 20 mm

Pulverization of Coal

Coal is send to furnace with the help of FD fan

Steam is generated at 540°C and 135 kg/sq.m

Steam is send to Super heater

Superheated steam is send to turbine

Production of Electricity by the generator coupled with

Elements Of Thermal PowerStation• Coal c onve yor    • Pul v er i s e r  • Boi l er  • Ec onom i s er• De ae r a to r• Coo l i ng t owe rs• G e ne r a tor  • Tr an s f or me r s  

• Coal conveyor : This is a belt type of arrangement. With this coal is transported from coal storage place in power plant to the place near by boiler. 

• Pulverizer : The coal is put in the boiler after pulverization. For this pulverizer is used. A pulverizer is a device for grinding coal for combustion in a furnace in a power plant

• Boiler: Now that pulverized coal is put in boiler furnace. Boiler is an enclosed vessel in which water is heated and circulated until the water is turned in to steam. Coal is burned inside the combustion chamber of boiler. The products of combustion are nothing but gases. These gases which are at high temperature vaporize the water inside the boiler to steam.

• Economiser: . Function of economiser is to recover some of the heat from the heat carried away in the flue gases up the chimney and utilize for heating the feed water to the boiler. The use of economiser results in saving in coal consumption , increase in steaming rate and high boiler efficiency but needs extra investment and increase in maintenance costs and floor area required for the plant. This is used in all modern plants.

Deaerator:Generally, power stations use a Deaerator to provide for the removal of air and other dissolved gases from the boiler feed water. A deaerator typically includes a vertical, domed deaeration section mounted on top of a horizontal cylindrical vessel which serves as the deaerated boiler feed water storage tank.

• Cooling Towers it is a tower- or building-like device in which atmospheric air (the heat receiver) circulates in direct or indirect contact with warmer water (the heat source) and the water is thereby cooled. A cooling tower may serve as the heat sink in a conventional thermodynamic process, such as refrigeration or steam power generation, and when it is convenient or desirable to make final heat rejection to atmospheric air. Water, acting as the heat-transfer fluid, gives up heat to atmospheric air, and thus cooled, is recirculated through the system, affording economical operation of the process.

Turbine: A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion

• Generator : An alternator is an electromechanical device that converts mechanical energy to alternating current electrical energy. In principle, any AC generator can be called an alternator, but usually the word refers to small rotating machines driven by automotive and other internal combustion engines.

• Transformers :It is a device that transfers electric energy from one alternating-current circuit to one or more other circuits, either increasing (stepping up) or reducing (stepping down) the voltage. Uses for transformers include reducing the line voltage to operate low-voltage devices and raising the voltage from electric generators so that electric power can be transmitted over long distances.

Distributed control systems

BASIC DCS

A Distributed Control System is a system which controls the plant process. It is composed of a set of processors, input modules, output modules, printers and workstations that are interconnected by a communication network.

A Processor consists of a microprocessor-based CPU and a memory unit. In the memory unit, EPROM or ROM is typically used to store programs that are closely related to the operation of the processor.

ADVANTAGES OF DCS

Control function is distributed among multiple CPUs (Field Control Stations). Hence failure of one FCS does not affect the entire plant.

Instruments and interlocks are created by software.Generation and modifications of the interlocks are very

flexible and simple.Information regarding the process is presented to the user

in various formats.Maintenance and troubleshooting becomes very easy.Cost effective in the long run.

Drawbacks of DCS:

If the CPU fails the entire plant gets affected.Redundancy concept was not available. 

THANK YOU