Syallabus of PGDC

NATIONAL POWER TRAINING INSTITUTE POST GRADUATE DIPLOMA COURSE IN THERMAL POWER PLANT ENGINEERING
SYLLABUS
Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Subject / Module - First Semester Power Plant Introduction & Industrial Safety Power Plant Familiarisation Power Plant Briefing & Scheme Tracing Power Plant Operation Rotation On-job(Operation) Erection, Commissioning & Construction Management Power Plant Performance & Efficiency Calculation Power Plant Chemistry , Metallurgy ,NDT & Welding Gas turbine & Combined Cycle Power Plant Advanced Steam Generation TechnologySupercritical and FBC Business Communication & Personality Development First Semester Examination Subject / Module - Second Semester Power Plant Protection Energy Audit Maintanence Planning & Cost Control Nuclear Power Plant Familiarisation Renewable and Hydro Power Plants Maintanence Practice & Inspection Design Analysis Load Despatch Power Reforms and regulations Control & Instrumentation IT Application in Power Sector & GIS Environment Management Rotational On Job(Maint.) Training & visit to Mfrs. Works Simulator Project Presentation Margin For Holidays Second Semester Examination Total
No. of Weeks 1 6 2 2 5 2 1 2 1 1 1 1 1 1/2 1 1 1 4 1 1 1 2 2 1 4 2 2 1/2 1 1 52
NATIONAL POWER TRAINING INSTITUTE POST GRADUATE DIPLOMA COURSE IN THERMAL POWER PLANT ENGINEERING Scheme of Examination
No. of Week s Intern al Test Max marks Exter nal exam Max Marks Total Max marks Remarks
Paper No.
1 2 3 4
Title of the Paper - First Semester Power Plant Familiarisation-I (Power Plant Introduction & Safety, Generators & transformers) Power Plant Familiarisation-II (Boiler, Turbine & BOP) Power Plant Operation, Power Plant Performance & Efficiency Calculation Erection, Commissioning & Construction Management, Gas turbine & Combined Cycle Power Plant Power Plant Chemistry, Metallurgy, NDT & Welding, Advanced Steam Generation Technology- Supercritical and FBC Rotation On-job(Operation) (Based on Viva Voce) Power Plant Briefing & Scheme Tracing (Based on Viva Voce) Business Communication & Personality Development (Based on Viva Voce) Total First Semester Examination Title of the Paper - Second Semester
3 4 3 3
50 50 50 50
100 100 100 100
150 150 150 150
5 6 7 8
3 5 2 1
50 50 50 50
100 100 50
150 150 100 50 1050
1 2 3 4 5. 6 7 8
Power Plant Protection, Control & Instrumentation, Energy Audit Maintenance Planning & Cost Control, Environment Management, Nuclear Power Plant Familiarization, Renewable & Hydro Power Plants Maintenance Practice & Inspection, Design Analysis Load Dispatch, IT Application in Power Sector & GIS, Power Reforms & Regulation Rotation On-job(Maintenance) (Based on Viva Voce) Training & visit to Mfrs. Works (Based on Viva Voce) Simulator Project (Based on Viva Voce) Margin for holidays Second Semester Examination
3.5 4 5 4 4 2 2 0.5 1 1
50 50 50 50 50 50 100 50
100 100 100
150 150 150
100 100
150 150 50 100
100
150
1050 Total 52 Distinction -75% and above First Division -60% & Above Second Division -50% to less than 60 % Pass Marks -Minimum 45% in internal & external examination separately and 50 % in overall Semester A student failing in a particular semester in three or more subjects will have to repeat the Semester exam with the next batch. A student failing in a particular subject will have to appear in the subject exam.
RULES AND REGULATION

A.
1.
ADMISSION AND ELIGIBILITY

The duration of the course leading to the Post Graduate Diploma In Thermal Power Plant Engineering shall be one academic year(52 weeks) divided into two semesters. A candidate shall have to pass all the two semester examinations within a maximum period of three years of his/her admission to the first semester of Post Graduate Diploma In Thermal Power Plant Engineering programme failing which he/she will be deemed to be unfit for the programme. However, a candidate, who having passed the first semester examination discontinues his studies, for legitimate and justified reasons may be permitted to join second semester within one year of his passing the first semester examination.
2.
The minimum qualifications for admissions to the first semester of Post Graduate Diploma In Thermal Power Plant Engineering programme shall be a Bachelor degree in Engineering or AMIE or equivalent degree in Mechanical, Electrical, Electronics./Control & Instrumentation/ Power Engineering. Those appearing in their final year examination may also apply. However, they must submit their result at the time of counseling. The Admission to this P.G. Diploma will be done on the basis of Merit based on a Common Entrance Test (CET) followed by counseling. CET will be conducted on rotation basis by the Institutes in the sequence New Delhi, Nagpur, Neyveli and Durgapur respectively.
3.(a) The first semester examination shall be open to a regular student who I) II) III) IV) (b) has been on the rolls of the Institute during the first semester; has at least 75% attendance in the class during the semester; has obtained pass marks in the internal assessment/ workshop/practical exam. and bears a good moral character
The second semester examination shall be open to a regular student who: i) ii) iii) iv) has been on the rolls of the Institute for the concerned semester has at least 75% attendance in the class during the semester; has passed the first semester examination and bears a good moral character.
B. 4.
EXAMINATION AND FEES Every candidate shall be examined in the subject(s) as laid down in the Scheme of Examinations/Syllabus prescribed . Course/Tuition fee should be divided equally into two parts. Semester 1 fee should be deposited at the time of counseling. Semester 2 fee should be deposited by 20th February of each year failing which a late fee of Rs.100/- per day may be charged. Each PGDC student will be charged a fee of Rs 200/- per subject as examination fee which 3
may be deposited one month before start of the semester examination ie. Rs. 1600/- for first semester and Rs 1600/- for second semester. 5. The external examiner(s) will set the question papers as per the criteria laid down in the Scheme of Examination for the program. Evaluation of semester exam answer sheets will not be done in the same Institute. All the written semester exams will be of three hour duration. The medium of instruction and examination shall be English. Mobile phones, any extra piece of paper, notebook are banned in the exam hall. A student indulging in exam malpractices may be expelled by the invigilator/Chief Supdt. for one year from the exam and he will be able to take the semester exams only after one year. The amount of examination fee to be paid by a candidate for each semester shall be as per the decision of NPTI from time to time.
6. 7.
8.
9. The Examination for the first semesters shall ordinarily be held in the month of January and for the second semester in the month of July or on such dates as may be fixed by the Director General, NPTI. Supplementary examinations will be held for re-appear/failed candidates as under:Semester When held
(a) First Semester Along with the Second Semester (b) Second Semester Along with the subsequent first Semester _________________________________________________________ 10. The Course Coordinator of the concerned Institute shall forward the internal test marks to the Principal Director/ Director at least one week before the commencement of each semester examination alongwith list of the eligible students who have satisfied the requirements of rules for appearing in the Examination. 11. (i) As soon as possible, after the competition of the examination the Principal Director/ Director shall publish a list of candidates who have passed the Semester Examination. (ii) Each successful candidate shall receive a copy of the detailed marks card on having passed the Semester Examination. 12. The list of successful candidates after the Second semester examination shall be arranged as under in two divisions on the basis of the aggregate marks obtained in the first and second semester examinations taken together and the division obtained by the candidate will be stated in his certificate. a) b) Those who obtain 50% marks but less than 60% marks SECOND DIVISION; Those who obtain 60% or more marks 4
FIRST DIVISION; c) Those who pass all the two semester examinations at the first attempt obtaining 75% or more marks in the aggregate shall be declared to have passed with - DISTINCTION
C. 13. (i)
EVALUATION The Principal Director/ Course Coordinator of the Institute will preserve the records on the basis of which the, Internal Assessment awards have been prepared upto one month from the date of declaration of the semester examination results. This record will be disposed off after one month. The first Semester results must be declared before 20 th of February of each year. (i) The internal assessment/practical/workshop/training report/project report award of a candidate who fails in any semester/paper(s) shall be carried forward to the next examination. Candidate(s) who has not obtained pass marks in the Internal Assessment in any paper(s) will not be allowed to take examination in the said paper(s) in the relevant semester. He/she will, however, be provided opportunity to appear before the Committee of Examiners, to be constituted by the Principal Director/ Director of the concerned Institute to re-assess performance of the candidate and the internal assessment given by the Committee shall be final. A candidate who fails to obtain pass marks in training report/project report shall be offered opportunity to undergo training again and conduct another project as the case may be and the same shall be assessed by a board of examinations appointed by the Principal Director. A candidate who fails to obtain pass marks in ROJT/practical/viva-voce shall have to re-appear before the board of examiners constituted by the PD/Director. The candidate shall be required to submit three copies of his Project Report. The last date for receipt of Project Report in the office of the Institute shall be one week before the commencement of the Second semester Examination. In exceptional cases, the Director General may, on the recommendation of the Principal/Director of Institute, extend the last date of receipt of the project Report, till the commencement of the Second semester examination, with late fee. (ii) The Project Report shall be evaluated as per the guidelines specified in the Scheme of Examination, jointly by the external and the internal examiners. The appointment of the external examiner shall be made by the Director General on the recommendation of the Principal Director of the respective institute. 5
14.
(ii)
(iii)
(iv)
15.
(i)
(iii)
The marks obtained by the candidate for the project report shall be taken into account when he appears in any future examination under reappear clause. The comprehensive viva-voce/workshop shall be conducted by a Board of Examiners to be appointed by the Director General on the recommendation of the Principal Director/Director of the respective institute consisting of the following members:i) ii) One Internal Faculty nominated by the Director of the concerned Institute; One or Two External Examiners from the Industry/Academic field
16.
(a)
(b)
The marks obtained by the candidate for the viva-voce/workshop shall be taken into account when he appears in any future examination under re-appear clause.
17.
The Project Report and Training Report, wherever specified will be submitted in the typed form as per the following requirements: (i) (ii) (iii) (iv) (v) (vi) The typing should be done on both sides of the paper (instead of single side printing) The font size should be 12 with Times Roman Format. The Project Report/Training Report may be typed in 1.5 (one and a half) space. But the References/Bibliography should be typed in single space. The paper should be A-4 size. Two copies meant for the purpose of evaluation may be bound in paper-back form and one copy should be in hard binding. Students will select topic of the project by 30th October of each year. Course Coordinator will submit the consolidated list of project with name of students to the Principal Director/Director on first working day of November.
D 18.
PROMOTION AND REAPPEAR The minimum percentage of marks to pass the examination in each semester shall be :a) b) c) d) 45% in each written paper and internal assessment separately; 45% in Training Report/Project Report and Viva-Voce separately. 50% in the total of each semester examination. A candidate who has secured minimum marks to pass in each paper but has not secured the minimum marks required to pass in aggregate for the semester concerned may take re-examination (in not more than two papers) to obtain the aggregate percentage required to pass the semester.
19.
A candidate whose result is declared late without any fault on his/her part, may attend classes for the next higher semester provisionally at his own risk 6
and responsibility, subject to his/her passing the concerned semester examination. In case a candidate fails to pass the concerned semester examination, his/her attendance/internal assessment in the next higher semester in which he was allowed to attend classes provisionally will stand cancelled. 20. A candidate shall be promoted to the next higher semester if he/she passes at least 50% of the theoretical papers (i.e. excluding subjects in which marking is done on the basis of Viva Voce) having prescribed in the semester, failing which he/she shall be declared as FAIL in that semester and he/she shall be required to appear in the failed semester in all the papers currently in force as, a private candidate (as ex-student). EXPLANATION : 50% of five papers will be taken as three and that of seven papers as four and that of nine papers as five under this Clause. E. OTHER PROVISIONS 21. Question paper for the External exams will be common for all the institute and will be set by a faculty who will be paid honorarium of Rs. 2500/- per subject plus postage charges on actual basis. Question paper setting will be responsibility of one of the institute on rotation basis ie. New Delhi, Nagpur, Neyveli and Durgapur respectively. Question papers will be broadly subjective in nature. 22. Answer sheets of the Semester exams will not be evaluated in the parent institute and sent for outside evaluation. The evaluator will be paid an honorarium @ Rs. 40 per copy plus postage on actual basis. For evaluating the project report or conducting viva voce the external and the internal examiner will be paid honorarium of Rs. 40/- and Rs. 20/- respectively per student plus TA. Similarly faculty evaluating for simulator will be paid honorarium @ Rs. 20/- per student. 23. The invigilators in the semester exams will be paid a honorarium of Rs. 200/per sitting of 3 hour. For 30 students one invigilator, for 30-60 students two invigilator and for more than 60 students 3 invigilators may be employed. Principal Director/ Director in-charge will act as Chief Superintendant of the examination and will be responsible for smooth conduct of examination and shall be paid a lump sum honorarium of Rs 2000/- for the semester final exams. A centre clerk and two peons (for sealing, water serving etc.) may be appointed by the Chief Supdt. for conduct of semester examination and may be paid an honorarium of Rs.120/- and Rs.50/- per sitting respectively. The centre clerk will assist the Chief Supdt. in making seat plan, maintenance of files (attendance, billing, dispatch of answer sheets etc.) for the exams. 24. Tabulation of the internal and external marks will be done by a faculty and shall be paid honorarium @ Rs. 20 per student. He will be responsible for collecting all the marks and tabulation and publication of the final result. The Principal Director /Director Incharge will nominate the tabulator of their respective institute. The tabulation records of the passed out students will be kept with Training Officer/Course Coordinator of the respective institutes. 7
25. A sumptuary allowance of Rs.1000/- per month may be granted to the course coordinator of PGDC in TPPE at the respective institutes and this expenditure will be met from the examination fee collection. The Course Coordinator will maintain the records of registration, feedback (to be taken once in each semester) and will prepare the day wise module of the course and intimate the faculty for their lectures. 26. Instruction For The Question Paper Setter: The question setter will set two sets of question paper for each subject and mark on the envelop Set A and Set B and seal them separately. The sealed Envelops For Set A and Set B should be sealed in a bigger envelop and sent to the respective principal director. The Paper setter should maintain the confidentiality of the question paper and all rough worksheets should be destroyed. The question should be broadly subjective in nature and should cover all parts of the syllabus. The maximum marks for each subject is 100 and pass marks is 45. The time allowed for each paper will be 3 hours. The subject syllabus can be identified by the following help: Power Plant Familiarisation I: This includes the General Introduction module, Industrial Safety module and 5th and 6th week module of Power Plant Familiarisation. Power Plant Familiarisation II: This includes 1st to 4th week module of Power Plant Familiarisation All other subjects have nomenclature pertaining to the modules which have been included. 27. The corporate quality committee will meet every year in the last week of July to review the status of the course. 28. Any other provision not contained in the above shall be governed by the rules and regulations framed by NPTI from time to time.
FIRST SEMESTER PGDC IN TPPE
Module : General Introduction (Duration): week

FORENOON DAY-1 DAY-2 Registration and Inauguration , Course Description, Institute facilities Site Selection (Site availability, Raw material, Fuel, load evacuation, Water, Transport, Pit Head Station ,Air Pollution, Topography, Skilled manpower ). General layout of a Thermal Power Station (Block Diagram of main equipments, Generator and their Auxiliaries) Growth of Independence AFTERNOON power Industry after
Coal to Electricity (Coal /Air / Flue/ Gas/ Water / Steam Path ,Brief description of main equipments involved in a Thermal Power plant Station ) Visit to Thermal Power Station
DAY-3
10
Module : Industrial Safety (Duration): week

FORENOON DAY-1 Accidents (Causes & Factors, Cost of Accidents , Accidents Prevention, Investigation of Accidents, Reporting and Recording Systems of Accidents) Fire fighting (Fundamentals of Fire, Fire Fighting Equipments and systems, Fire Extinguishing Methods, Demonstration of various fire.) AFTERNOON First Aid (Basics of First Aid, How injuries are caused in lifting, falls etc.)
DAY-2
Industrial Safety & hazards(Industrial Hazards ,Protective Clothing and Equipment, Safe work practices in power Plants, permit to work system, safety in moving and storage of materials, Housekeeping Safety rules)
11
Module : Power Plant Familiarization (Duration): 6 week

FORENOON DAY-1 Steam Cycle Theory (Carnot cycle , Rankine cycle, with reference to a specific unit 500/210 MW , steam properties) Coal Handling system (Location and layout, Main Equipments and their functions , Coal transportation , preparation, storage and reclamation , MGR system, safety aspects , Fire prevention and fire fighting in coal handing plant ) Fuel Oil Systems (Location and site selection, Type of fuel used , Main equipment and their functions Transportation, handling , storage Fuel oil preparation before firing) Description of Main Boiler (Classification and Types, Arrangements of main boiler , Fundamentals of Boiler design , Location of various pressure parts) Constructional detail of Super heaters, Re heaters, Economizers, De super heaters. AFTERNOON Coal (Types of coal and their characteristics, Their suitability for different kinds of Boiler, Alterations in firing methods due to change of coal composition) Combustion Theory(Definition , Combustion requirements, factor influencing combustion, combustion of fuels , gross and net calorific value)
DAY-2
DAY-3
Plant visit (visit to coal handling plant, visit to fuel oil station)
DAY-4
Boiler Circulation Theory (water walls boiling phenomena , Nucleate / Film boiling , Natural / Controlled / Forced circulation )
DAY-5
Steam Separation theory ( Boiler Drum & its internals)
12
Module : Power Plant Familiarization (Duration): 6 week 2 ND WEEK

FORENOON DAY-1 Audio-visual / CBT Session on Drum and Drum internals Various Fans and their salient features (Construction detail / lubricating oil system for PA fan, FD, ID fan) Ventilation and Air conditioning AFTERNOON Draught system (Theory of natural, induce, balance and forced draught , Drought loss stack effect) Air Pre heaters(Types And Functions Constructional Details, SCAPH. Soot Blowers.) Pulverizes and Feeders (Classification Of Mills ,Constructional features of Bowl mill Pulverization of Coal, factors affecting Milling Plant Performance, Coal feeders and its type) Electrostatic Precipitator (ESP) (Need of fly ash separation, working principle , corona effect, constructional details, Rapping mechanism)
DAY-2
DAY-3
DAY-4
Fuel Firing Arrangements and Burners (corner front and rear wall firing , Direct and indirect , Details of coal and oil burners Burners tilting Mechanism , Atomization of fuel oil burners and igniters ) Ash Handling System (Fly ash handling system, Bottom ash disposal system , Ash handling plant operation ,Ash handling pump, Disposal of ash slurry ,utilization of ash)
DAY-5
Plant visit (Milling plant, Main Boiler and Fans, Ash handling).
13
Module : Power Plant Familiarization (Duration): 6 week 3RDWEEK

FORENOON DAY-1
Furnace, Safeguard, supervisory System (Description of field equipments (no C&I )
AFTERNOON Audio Visual Session (FSSS)
DAY-2
Water Supply System (soft water, clarified water, cooling water, D. M water) Description of main components i.e. Turbine casing, rotor steam admission valves, couplings , bearings etc. Steam condensation and Condensers(film wise/drop wise condensation, Direct/ indirect condensation and vacuum creation) Power Station Pumps (Classification of pumps, Centrifugal pumps, positive displacement pumps)
Steam Turbines (Classification of Turbines Metallurgical considerations, Working Principles Turbine lubrication Oil System Construction and working Principles of main Oil pumps , Oil coolers) Audio-visual (vacuum System, Turbine lubrication Systems
DAY-3
DAY-4
DAY-5
Boiler Feed Pump (Function of BFP Constructional details)
14
Module
: Power Plant Familiarization (Duration): 6 Weeks
DAY - 1
4TH WEEK FORENOON AFTERNOON . Circulating Water System (Open/ Plan Visit (CW System including Closed system, CW Pumps, Cooling Cooling Towers, CT Pumps, CT Towers, CT Pumps, CT Fans) Fans, Condenser Vacuum Ejectors, BFP) Regenerative Feed Heating System (Working Principle and constructional details of L.P. Heaters, Deaerators, H.P. Heaters GSC, Ejector) Visit to (Regenerating Feed Heating System, Turbine Lubricating Oil system, Water Treatment Plant) Governing System
DAY - 2
DAY - 3
Turbine Governing System ( Types of Turbine Governing systems. Various (Contd.) components, systems and their functions, Oil circuit for Governing System. Overall working of governing system with reference to load throw off. Load raising). Audio/Visual Session on Governing System.
DAY - 4
HP/LP Bypass system and PRDS and its utility, Various interlocks and protections
DAY 5
Audio/Visual Session on HP/LP By Plant visit (Governing System and pass System. HP/LP By pass System).
15
Module
: Power Plant Familiarization (Duration) : 6 Weeks
DAY - 1
5TH WEEK FORENOON AFTERNOON Generator Constructional Details Tutorial/General discussion. (Basic principle of electricity, generation Development of generator design, Construction details of rotor, stator etc. Hydrogen Cooling System and Stator Audio visual on Hydrogen cooling Water Cooling System (Different types system of cooling arrangements for rotor and stator, Selection and properties of coolant, Air cooling, Hydrogen cooling, Stator water cooling, H2 Charging/ Purging Cycle). Hydrogen Seal Oil System (Details of the system, Function and purpose of differential pressure regulator and pressure oil regulators, Types of Hydrogen seals and their construction details). Audio/Visual Session on Excitation System. Generator Excitation System and AVR (Principles, Simple arrangemnts of excitor and its field winding, Classification of excitation system High Frequency / static excitation system - their merits and demerits, Automatic Voltage Regulator). Plant Visit (Generator and Auxiliaries, Hydrogen cooling & Stator Water Cooling System, Hydrogen Seal oil system).
DAY - 2
DAY - 3
DAY - 4
DAY 5
Transformers (Working Principles, Audio/Visual/Discussion session. Various types of transformers used in a power station, Constructional features of main transformer and accessories, Bucholtz relay and main protections, Types of cooling, Mulsifire and other fire protection systems.
16
Module
: Power Plant Familiarization (Duration) : 6 Weeks
DAY - 1
6TH WEEK FORENOON AFTERNOON Motors (Fundamentals, Constructional Plant visit (Transformers details of HT/LT Motors, Various Excitation System) motors used .in Power Stations. HT-LT Supply system/DC Supply Audio visual on electrical System. System (A typical layout of 6.6 KV, 3.3 KV and 415 V supply system in a TPS, DC Supply system in a TPS . Switchyard (A typical layout of Plant Visit (Switchyard, HT/LT Switchyard of a Thermal Power System, DC Supply System). Station, Bus system, Isolators, CTs, PTs, Earthing, Oil Circuit Breakers, Air Blast Circuit Breakers. SF6 Circuit Breakers). Audio/Visual Session Written Appraisal. Discussion
DAY - 2
DAY - 3
DAY - 4 DAY 5
17
Module
: Scheme Briefing & Tracing (Duration) : 2 Weeks 1ST
DAY - 1
WEEK FORENOON AFTERNOON Scheme briefing in class room on Class Room briefing on Fuel oil Boiler Drum connections, Feed system and milling system. regenerating Heating System, Air and Flue Gas Path. Class Room briefing on Main steam. Cold reheat, Hot reheat lines, condensate & feed water lines, BFP, CW schemes. Scheme Tracing: Coal Handling, Receiving points. stocking lines, weighing, sampling. Screening, crushing, bunker filling, conveyors, tension arrangement for conveyors. Boiler - Feed Water Schemes (Feed control station arrangement, economiser connections, economiser recirculation lines, boiler drum, water wall connections; drain header, blow down lines, CBD, IBD, SH/RH, attemperator station). Air and Flue Gas Schemes (ID,FD, PA fans and their control system including Seal air/ Scanner air/ Igniter air Fans/Systems/ Damper control for secondary air. Class Room briefing on Hydrogen cooling, stator water cooling, seal oil system, switchyard, AC/DC auxiliary power supply system, Oil Handling (Unloading arrangements, oil tank mountings, oil pump house connections, tank heating. pipe line layout with provisions for expansion.). Steam Schemes (MS, CR & HRH lines up to turbine control valves including HP/LP by pass, location of safety valves, vents and drains, auxiliary PRDS schemes, auxiliary steam distribution, soot blowing steam lines). Fuel Schemes (Scheme of RC bunkers and RC feeders, Coal mill connections. Light oil and. atomising air system, location of trip valves, air control valves, nozzles valves and igniters. Heavy oil and atomising steam system).
DAY - 2
DAY - 3
DAY - 4
DAY 5
18
Module
: Scheme Briefing & Tracing (Duration) : 2 Weeks 2ND WEEK AFTERNOON Ash Handling System - Bottom Ash and Fly ash disposal system hoppers/Clink grinder, HP/LP water injection, Ash slurry pumps etc.
DAY - 1
FORENOON Water Treatment Plant (Raw water tanks to DM Water storage tanks, arrangement of Pressure sand/Activated carbon filters, cation, anion, mixed beds, degassifier, back washing system, regeneration, Phosphate and Hydrazine dozing scheme. Steam Extractions and Drains (Schemes of turbine extractions, FCNRVS, Heater drain connections, HP/LP drips. Schemes for heating flanges and studs. Steam connections/condenser air line connections to ejectors, Unit drain tank/flash tank connections).
DAY - 2
Condensate and Feed Water Schemes (CEP connections, scheme of condensate flow, ejectors, gland steam coolers, LP heater, deaerator connections. Scheme of Feed Water flow, BFP connections, Feed water connections to HP heaters, Location of valves, interconnections, by pass arrangement for heaters) CW System and Cooling Towers (locating moving screens, CW Pumps, Venting arrangements, Valve locations, Chlorination schemes).
DAY - 3
Turbine Oil System (Turbine lube oil schemes, lube oil purification schemes, location of MOT & lube oil pumps, Oil coolers, cooling water connections.
DAY - 4
Generator (Seal oil scheme, Hydrogen Switchyard (GT to feeder line scheme, Stator water cooling schemes, arrangements, locating various Excitation arrangements). transformers (GT, UA SAT, CTO, PTO), switchgears, isolator earthing arrangement, buses etc Power Supply (6.6 KV Viva-voce. schemes/ 420 V Schemes, arrangement of breakers, buses. DC system, battery bank arrangement).
Auxiliary
DAY 5
19
Module
: Power Plant Operation (Duration) : 2 Weeks 1ST WEEK
DAY - 1
FORENOON Availability of electrical supply to the equipment (source feeder of each equipment, points of the isolation of the equipment, locking during isolation, permit to work system).
AFTERNOON Boiler pre light up checks. (Meaning of line up, shut down, tripping, starting etc. no pending permits, Local checks.)
DAY - 2
Operation of service auxiliaries Operation of air-pre heater and ID (cooling water pump, compressors, fans, pre checks, flow path line up, auxiliary steam, fuel oil pumps. permissive interlocks. Operation of FD & PA Fans (Pre Mill operation (Pre checks, flow checks, flow path line up, permissives, path line up, permissives. interlocks). interlocks). FSSS (Secondary air, burner tilt, fuel Drum level control, Super heater/ and air control). Re-heater temperature control and their interlocks. Operation of turbine lub oil system and Operation of condensate and feed barring gear. water system (BFP Heaters, CEP).
DAY - 3
DAY - 4
DAY 5
20
Module
: Power Plant Operation (Duration): 2 Weeks
DAY - 1 DAY - 2 DAY - 3 DAY - 4
2ND WEEK FORENOON AFTERNOON HP/LP Bypass operation and turbine Turbine rolling and heating. synchronisation. Operation of generator cooling Operation of Generator Excitation system (stator and hydrogen cooling). System, AVR. Operation of turbine governing system. Integrated operation of unit (unit loading and shut down sequence). Operational difference between Cold Load dispatching and coordination start up, Warm start up and Hot start with load dispatch centre. up. Power Plant Emergencies (Boiler & Discussion and appraisal. Turbine).
DAY 5
21
Module
: ROJ (OPERATION) (Duration): 5 Weeks
DAY - 1
1ST WEEK FORENOON AFTERNOON Working with Boiler Firing floor Operator : Continue..... (Cleaning of oil guns/Filters and their trial run, Checking feed control valves, blow down valves, air vents, coal feeders, secondary air dampers, ash level in economisers hoppers, Operation of Blow downs, chemical dosing valves operation, Charging of drum gauge glass aux. steam for soot blowing). Working with Coal Mill Operator (Shift taking Continue ..... over/handing over checks, Pre start checks, Routine checks, Mechanical Isolation of mills, Cold and hot air damper operation, Activities during emergency in mill area, Changing over of seal air filter, Oil filling into mill gear box).. Working with. Ash. Disposal operator Continue ..... (Checking for Shift taking over/handing over, Routine check (Note atleast one reading), Ash flow rate in full load and partial load unit operation (from Bottom ash and ESP Hoppers etc., ESP field electrical system, Isolation and charging of ESP fields, Ash disposal urn Color of Ash Working with Boiler Fans Operator (Checking Continue ..... -for shift taking over and handing over, Routine checks (Note: atleast one reading), Isolation of ID,FD,PA fans, Charging of lube Oil system, Change over of lube oil pump) Working with Compressor Operator (Shift Continue ..... handing over/taking over checks, Routine checks (Note: atleast one reading), Charging of Drier, Regeneration of Drier, Starting and stopping procedure. Emergency operation.
DAY - 2
DAY - 3
DAY - 4
DAY 5
Note:- The students shall Undertake the 'Rotational On-job Training (Oprn),in the Power Station identified by the concerned NPTI. The course Co-ordinator shall make the appropriate shift roaster suiting to local conditions/shift roaster of the power plant.
22
Module : ROJ (OPERATION) (Duration) : 5 Weeks DAY 6 2ND WEEK FORENOON AFTERNOON Working with Boiler side supervisor Continue ..... (Shift taking over/handing over checks, Coordination with local operators, Reporting to Control Room,. Routine checks (Note: atleast one reading). Working with Boiler Control Desk Continue ..... Operator (Shift handing/taking over checks, Receiving site report from operators and supervisor concern, Logging of parameter (Note: atleast one reading), Operation procedure of different equipment Working with Boiler Control Desk Continue ..... Operator (Shift handing/taking over checks, Receiving, site report from operators and supervisor concern Logging of Parameter (note: atleast one reading), Operation procedure of different equipment. Working with CEP Operator (Shift Continue ..... handing over and taking over, Routine checks, Chemical dosing pump, starting procedure and making of chemical solution, Checking of make up and other controller, Priming of water box, Start of ejectors, Charging of LP Heat Working with BFP Operator (Shift Continue ..... handing over and taking over, Routine checks (Note: atleast one reading), Precheck for starting BFP, Charging of lub oil system, Change over of filters, checking of control v/vs., Operation of Recirculation valves, Charging Isolation of HP Heaters, Deaerator water heating, Aux.. steam charging/isolation) Valve
DAY 7
DAY 8
DAY 9
DAY 10
23
Module : ROJ (OPERATION) (Duration) : 5 Weeks DAY 11 FORENOON Working with Turbine Operator (Shift handing over & taking over, Routine checks (Note: one reading), rechecks for starting lub oil system, Filling of oil in Main Oil Tank, AC, DC, Jacking oil pump checks, Instrumentation fitted with main oil tank, Parameters of Governing system, Charging and isolation of governing system, ESV, IVs and control V/Vs, local operation, HP/LP By pass 3RD WEEK AFTERNOON Continue .....
DAY - 12
Working with Generator Operator ( Shift handing Continue ..... and taking over, Routine checks, Pre start checking of seal oil, Hydrogen cooling, Stator water cooling system, Purging of H2 and C02 of Hydrogen cylinder charging, Cooler/Filter charging. Working with Turbine Supervisor (Shift handing/taking over, Routine checks by supervisor, Coordination with Operator, Reporting to Control Room) Working with Turbine Desk Operator (Shift handing Continue ..... over & taking over, Receiving report from supervisors and operators, .Logging of parameters, Operation Procedure of main equipment, ATT & ATRS operation, Emergency operation). Working with Electrician/Supervisor (Shift handing Continue ..... over and taking over, Routine check of Diesel set and other parameter, HT & LT Breaker Isolation and normalisation procedure, Charging of DC Batteries, Checking of GT, U AT and service transfolll1ers, Safety devices, Operation of switchgear compressor). Working with Electrical Desk Engineer Continue ..... (Shift handing over/taking over checks, Routine check (Note one reading), Operation procedure of various equipment at generator desk like excitation s stem. AVR etc).
DAY - 13
DAY - 14
DAY 15
24
Module : ROJ (OPERATION) (Duration) : 5 Weeks DAY 16 4TH WEEK FORENOON AFTERNOON Working with Hydrogen Plant Operator Continue ..... (Shift handing / taking over, Operation of H2 Plant, Filling operation of H2 cylinder, Analysis of H2and O2 concentration. Routine checks). Working Coal handling control room Continue ..... (Shift handing/taking over, Pre-checks of CRP equipment operation, Operation of Crusher, belt conveyor, tripper, flap gate, Unloading procedure of wagons, Magnetic separator and weighing arrangement, Routine checks, Bunker filling and level monitoring, Coordination with mines, unit incharge and shift incharge, Coal amt. recording, Reclaimer). Working with Switchyard Control Room Continue ..... Engineer (Shift handover/takeover, Routine check, Load schedule for the month, week and day, Load sharing by Units, Charging/isolation of HT Bus, Reporting to in house and external agencies about load schedule. operation of Isolators and brokers). Working with Cooling tower and cooling Continue ..... water pump operator (Shift handing over/taking over, Routine checks, Pre-start checks of CT and CW Systems, Starting/Isolation of cooling towers, CT .' Pumps, CW Pumps, Emergency operation, Lub oil system of C\V and CT Pumps. Working with Performance Monitoring Continue ..... Cell (Collection of information from each section, Programme for calculation (show at least one day calculation of all parameter), Analysis of result and comments preparation, Daily plant meeting (input and output), Reporting to concern about plant performance).
DAY - 17
DAY 18
DAY 19
DAY 20
25
Module : ROJ (OPERATION) (Duration) : 5 Weeks DAY - 21 5TH WEEK FORENOON AFTERNOON Working with Shift chemist (Shift Continue ..... handing over / taking over, Routine activities, Collection of samples of (Coal:-oil, H2, Drum Water, Steam Condensate etc.) (note down pt. of sampling), Analysis of sample (Note down the value), Action suggested to bring the concentration normal. Working with DM Plant chemist (Shift Continue ..... handing over and taking over, Routine checks, Storage tank. for clarified and DM water, Starting and Isolation of DM Water pump Regeneration of Ion Exchange Working with Unit Incharge (Shift Continue ..... hand over/take over, Investigation and reporting of plant defects and abnormalities. Issue and canceling of PTW, Hot and Cold startup of unit, Decision during emergency, coordination and reporting of problem to higher Management, Main parameters, monitored (take one reading). Working with Shift Incharge (Shift Continue ..... handing over / take over, Receiving report from unit Incharge, Instruction to SCE regarding load sharing, Reporting to higher management, Main parameters monitored (take one reading). Working with Air-conditioning Apprasial/Disussions Operator (Shift hand over/take over. Routine checks (take one reading). Temperature Control, Humidity Control, Operation of AC Plant, Dust Control).
DAY 22
DAY - 23
DAY - 24
DAY 25
26
Module
: Erection, Commissioning & Construction Management

(Duration) : 2 Weeks
Erection, Commissioning
1st Week
DAY - 1
FORENOON Preparation of commissioning, trial run of various equipments, commissioning of valves, air and gas tightness test of boiler.
AFTERNOON Chemical cleaning of Boiler preparation for boiler light up, thermal flow test of water walls and economisers, steam blowing.
DAY - 2
Safety Valve setting, reliable run of Alkaline flushing and commissionboiler, Hydraulic test of boiler. ing regenerative system, acid cleaning of oil pipe lines, oil flushing procedure of lubricating oil and governing, system. Turbine Lubricating oil flow testing, Commissioning of governing steam blowing, reheater safety Valve system ATRS & ATT, and TSE. setting, vacuum tightness test ejector testing. Commissioning of generator and auxiliaries (Generator testing, rotor and stator cooling system, excitation system Commissioning of electrical system (Circuit breakers, isolators, CT and PT, rectifiers, switchgear DC system).
DAY - 3
DAY - 4
DAY 5
C&I Commissioning activities Discussion/Appraisal (Minimum instrumentation s required for major C&I commissioning, commissioning of control of valve, tuning of control valves).
27
Module
: Erection, Commissioning & Construction Management (Duration) : 2 Week Construction Management
2nd Week
DAY - 1 FORENOON AFTERNOON Construction, Site Organisation and Construction Contracts & Administration Estimating, Costing Contracting Construction Materials and Bidding and Construction Project Management Techniques Tendering, Bidding, Contract Laws & Claims Management Risk Management Project Risk Management Site Management, Construction Finance Management, and Cost Accounting Introduction to Construction Safety, Common Safety Hazards, Laws on Construction Safety, Health and Welfare, Safety Practices and Standards Construction site Personnel Management Manpower Planning Techniques Labour Laws for Construction Materials and Logistics Management, Project Management
DAY - 2
DAY - 3
DAY - 4
Introduction to Equipment and Machines used in power plant construction, Planning and Selection, Case Studies on Construction Equipment Planning and Selection
DAY 5
Construction Equipment Maintenance, Management Information Systems Case Studies on Construction in construction management, Equipment Maintenance Construction Quality Management, Productivity, Safety and Quality
28
Module
: Power Plant Performance and Efficiency Calculation (Duration) : 1 Week
DAY - 1
FORENOON Introduction, Need for performance monitoring, objective, controllable and un-controllable factors, basic requirements. Performance Monitoring of Boiler Auxiliaries (Pulverisers, Factors, sampling of pulverised coal, classifier adjustments, mill rejects, causes and remedies) Air Heaters (effect of AH outlet temperature, Performance tests) Fans (Performance, curves, optimum operation point.) Factors influencing performance of turbine( Steam pressure, temperature and Back pressure, cylinder efficiency, deposits on turbine blades, blade roughness, effect of tubes) Turbine Losses..
AFTERNOON Factors influencing performance of Boilers and Optimisation (Fuel properties, excess air, fineness of PF etc.) Boiler efficiency calculation (Direct method calculation, limitations in adopting direct method, (Losses method, Other standard method.)
DAY - 2
DAY - 3
Factors affecting performance of condenser and feed heater ( TTD, CW inlet, temperature, CW flow, heat transfer across tubes) Heaters (air accumulation, steam side/ water side fouling, drainage, Effect of attemperation in reheaters). Heat balancing.
DAY - 4
Turbine heat rate calculations (Method Optimisation of auxiliary power parameters required). consumption (Scope, variable speed drives, operation of unnecessary running auxiliaries). Logging and recording (Scope of Discussion and appraisal. logging and recording, use of DAS/DDC in performance monitoring).
DAY 5
29
Module
: Power Plant Chemistry ,Metallurgy, NDT and Welding Duration : 2 Week Chemistry
DAY - 1
1/2 Week FORENOON AFTERNOON Basic chemistry (Atomic structure, Pre and post treatment of water. elements, compounds, mixtures, solutions, ionization, salts acids alkali pH values). Chemical control and treatment of Classification of coal & oil, their Boiler feed water and steam. Cooling sampling and analysis water treatment Corrosion theory and deposition
DAY - 2
DAY - 3
30
Module
: Power Plant Chemistry ,Metallurgy, NDT and Welding Duration : 2 Week Metallurgy 1 Week FORENOON AFTERNOON
Elastic and Plastic deformations, strain hardening and fracture Mechanical properties of materials Testing of materials.
DAY - 1
Introduction to Metallurgy and its relevance in power industry crystal structure - space lattices - crystal lattice imperfections - crystal structure under stress.
DAY - 2
Steel making - Microstructure Heat treatment and surface hardening Composition/property relationship of steel of steel failure mechanism - typical - effects of - alloying - power plant steels. such situations in a power plant. Non-ferrous metals and alloy's: Application of Non ferrous metals and alloys in PP condenser components conductors slot wedges in generator rotor pipe to pipe couplings - bearings. Copper, Aluminum, Nickel, Magnesium. Titanium and their alloys in properties of theses alloys failure mechanism. Non metallic materials : Use of plastics and rubber in PP Thermoplastics thermo sets rubbers their properties. Application, coatings, adhesive, linings, insulation seals, sealants, gaskets etc. Application of ceramics in Power Plant Insulation Refractory properties.
DAY - 3
DAY - 4
Material selection for Design Material Protective surface treatment. (Metal requirement, specification and relevant cleaning protective Metal coating, standards fro boiler, turbine, generator Fabrication of precoated metals). components Piping and Valves : Appreciation of component, fabrication metal forming, casting forging, pipe bending, tube manufacture. Defect analysis and life assessment. Low Group discussion and appraisal temperature behavior. high temperature behavior - defect assessment of solidification crack austenite stainless steel welds, cracking in CrMoV weldment etc. Thermal fatigue - various tests - Defects assessment route and calculation of damage. Remaining life assessment beyond design life of boilers, turbine rotors, generator rotors etc.
DAY 5
31
Module
DAY - 1
: Power Plant Chemistry ,Metallurgy, NDT and Welding Duration : 2 Week NDT & WELDING 1/2 Week FORENOON AFTERNOON Introduction to welding and types of Description of welding methods welding. generally used in thermal power station. Welding machines, types of electrodes, Purpose of NDT and types of precautions during welding process, defects cover by NDT. welding defects. NDT Methods used in power station (Principle, equipments, utilization, merits and de-merits).
DAY - 2
DAY - 3
32
Module
: Gas turbine & combined cycle power plant (Duration) : 1 Week 1st week
DAY - 1
FORENOON AFTERNOON Gas Turbine and Combined cycle Fuels for gas turbine plants, power plant-introduction, basic cycles physical and chemical properties and types of CCGT of fuels and their analyses Description and construction details of Gas turbine construction detailsCompressors blade materials and its selection, Description and construction details of cooling arrangement Combustors Gas turbine support system, inlet / Waste heat recovery steam exhaust systems, lube oil system, fire generator - Description and protection system, governing system construction details. Cogeneration plants. Emission control main emission Operation of Gas Turbine and products, its effects and control. CCGT plant- Pre checks, Startup and shutting down procedure including normal operation. Efficiency and performance Combined cycle power plant monitoring, optimization of CCGT, maintenanceplanning for performance testing. schedule maintenance, various checks, case study.
DAY - 2
DAY - 3
DAY - 4
DAY 5
33
Module
: Advanced Steam Generation Technology- Supercritical and FBC (Duration) : 1 Week
DAY - 1
FORENOON AFTERNOON Introduction to supercritical Arrangement of super critical technology, advantages-World boilers and their types. Comparison scenario in supercritical technology. between spiral water wall circulating and vertical tubing. Special alloys for super critical boilers Differences between Supercritical and welding techniques. and subcritical Technology
Introduction to FBC Technology Classification of FBC technology Advantages, Scope, Fuel flexibility etc boilers. Description of various components of CFBC Boiler Environmental benefits
DAY - 2
DAY - 3 DAY - 4
DAY 5
Limitations, major concerns in the O&M of Visit to Supercritical/FBC Boilers FBC Boilers
34
Module
: Business Communication & Personality Development (Duration) : 1 Weeks 1ST WEEK

AFTERNOON Assertiveness, Indicators of assertive behaviour, Strategies of assertive behaviour Business Etiquettes: Business dining, business manners of people of different cultures Non verbal communication: Continued.. voice modulation, Body sport for interviews, Written Communication contd. Business correspondence, business letter format, style of letter arrangement, types of letters, Viva Voce
DAY - 1
FORENOON Presentation Skills: Perquisites of effective presentation, Format of presentation Communication skills for Group Discussion and Interviews Non verbal communication: gestures, handshakes, glazes, smiles, hand movements, style of working, Written Communication: Mechanics of writing , report writing, circulars, notices, memos, agenda and minutes Written Communication contd.. Telex messages, facsimile, electronic mail, Developing Resumes
DAY - 2
DAY - 3
DAY - 4
DAY 5
35
SECOND SEMESTER PGDC IN TPPE
36
Module
: Power Plant Protection (Duration) : 1 Week
DAY - 1
FORENOON AFTERNOON Introduction (Terminology, Methods of system earthing and the Requirements of protective system, fault conditions, Lighting / Surge Historical developments) Protective Instrument transformers. Relays (Types and their applications, Construction, Maintenance requirements, Setting and testing). General Protection (Neutral earthing. Transformer Protection (Various Stator and rotor earth faults, Sustained protections, Protective systems for external faults, Instability, Protective Transformers, UATs & STs). systems used above). Motors (Faults systems). and protection Automatic Voltage (Requirements, types and function mechanical, electronic amplifier magnetic amplifier regulators, construction, maintenance and testing). Feeder Protection (Continuity of discrimination, Outline of Pilot wire, carrier current, protection, PLCC Tele communication).
DAY - 2
DAY - 3
DAY - 4
Bus bar Protection (Continuity of supply, Discrimination, Circulating current systems, Special features relating to different voltage - Pilot wire, carrier current, systems). protection, PLCC Tele Communication).
DAY 5
Visit to Power Station and Lab. Group discussion and appraisal. demonstration.
37
Module : Energy Audit (Duration): week

FORENOON DAY-1 AFTERNOON
Need for Energy Audit and Audit Procedures. Energy Audit Macro Level & Micro Level. Energy Saving methods with typical examples and exercises for power stations Energy Losses An Integrated optimal strategy for reduction of T&D Losses.
Energy Management System, Energy Auditing and their implementation techniques for power industries. Ways to minimize losses in power transmission & distribution system
DAY-2
DAY-3
38
Module
: Maintenance Planning & Cost Control (Duration) : 1 Week
DAY - 1
FORENOON AFTERNOON Aims and objective of maintenance Integration of maintenance with efficient service, high plant requirements, plant reliability, availability, maintenance learning plant and daily work programs. engineer's duties. Preventive maintenance of running Planning of major plant overhauls units. shutdowns. Planning techniques critical path Purchasing and stores controlanalysis, charting system etc. standards, cost codes. Control of stores and store records. Cost control. Direct costs, indirect Contract procedures (Conditions of costs, outage costs, budgeting and contract, capital applications and costing work, budgetary control. procedure, project evaluation, interest and depreciation charges). Role and application of Information Group discussion and Appraisal Technology in maintenance planning.
DAY - 2
DAY - 3
DAY - 4
DAY 5
39
Module
: Nuclear Power Plant Familiarization (Duration) : 1 Weeks 1ST WEEK
FORENOON DAY - 1
AFTERNOON
Introduction of nuclear energy, energy The fission process and fission from nuclear fusion, plasma, energy products, radioactivity, radioactive from nuclear fission materials Regulation for governing the Nuclear reactor and power plantproduction of power from nuclear fuel Reactor, general components of & safety aspect. National policy nuclear reactor. regarding Nuclear power generation. Pressurized water reactor (PWR), boiling water reactors (BWR) & Canadian deuterium uranium reactor (CANDU)-mass and heat balance, working principle and construction details Gas-cooled reactor, liquid metal cooled reactor - mass and heat balance, working principle and construction details, material for Gas-cooled reactor, liquid metal cooled reactor, advantages and limitation. Sodiumgraphite reactor SGR, fast reactors.
DAY - 2
DAY - 3
DAY - 4
Organic cooled and moderators Nuclear materials-nuclear fuel, reactor, Breeder reactors working coolant, moderating and reflecting principle and construction details, materials, shielding materials. material for reactor Nuclear waste & its disposal-types of Appraisal nuclear waste ,effect of nuclear radiation
DAY 5
40
Module
: Renewable Energy and Hydro Power Plants (Duration) : 1 Week FORENOON AFTERNOON
Wind Energy Systems
DAY - 1
Energy Sector Reforms, Regulations Environment and RE
DAY - 2
Solar thermal power systems
Direct energy Conversation - Solar Photovoltaic, Fuel Cells.
DAY - 3
Biomass Energy Systems.
Introduction of small, mini and hydro power generations
DAY - 4
Basic features of hydro Turbines
Hydrology and estimation of water potential
DAY 5
Site selection and Layout of Hydro power plants
Description of Hydro Interlocks and protection
Turbine
41
Module
: Maintenance Practice & Inspection (Duration) : 4Weeks 1ST WEEK
DAY - 1
FORENOON AFTERNOON Checking of Boiler tubes for external Hydraulic test, allowable rate of damage due to erosion or cutting. pressure drop. Checking of welds Method to overcome, e.g. pin holes. strengthening of tubes in the flow channels. External cleaning of boiler surface and water washing. Use of sky climber, Different types of tube failures creep overheating Checking of isolating and regulating dampers for leakage, proper alignment, adjustment for both under cold and hot operation conditions. Measurement of tube wall thickness, Checking of flue gas path for direct corrosion or erosion and leakage. PA, ID & FD fan check for inlet dampers bearing alignment, vibration both radial and axial shift of magnetic centre of motor and rotor, fan blade conditions mode of repairs, hard facing
DAY - 2
DAY - 3
DAY - 4
Checking of boiler mountings and their Checking the burner nozzle for adjustments (a) Gauges glasses, (b) burnout and reasons for the same Safety valves, their checking and and its metallurgy settings of safety valves for blow down and dropping Check the flow distribution in burners adjustment of orifices or valves check the burner flow direction and its adjustment, checking of burner chamber, dampers breakage of links and proper gauge operation Check the rollers or ball wear of coal mill also Ball ring segment wear. Keeping of capacity and hour of operation. Check roller thrust bearings and ring, seals
DAY 5
42
Module
: Maintenance Practice & Inspection (Duration): 4Weeks 2ND WEEK
DAY - 1
FORENOON Check the adjustment of roller of ball pressure check for leakage of coal and air around journal assembly main shaft and possible contamination of lubricating oil method for reservation
AFTERNOON Check the gear-box worm and worm wheel driver for wear and backlash allowable limits. Check classifier vane angular position proper operation and coal fineness
DAY - 2 DAY - 3
Air heater maintenance/trouble Soot Blowers Maintenance/Trouble shooting causes and remedies shooting causes and remedies Safety valve maintenance and its float Procedure for alkali boil out and procedures, trouble shooting/causes acid cleaning preservation and remedies flushing, Procedure for flushing and preservation both wet and dry Internal checking of drum and drum Boiler bottom air seal, proper and internals, Checking of at temperature free movement and expansion of including spray nozzle and shock linen boiler setting when hot. Normal water level and flow in bottom seal. Adjustment and prevention of dust accumulation in the seal chamber Maintenance of clinker grinder, bottom Furnace tightness checking, Bench ash hoppers maintenance of De- mark for draught loss for different watering pump slurry pumps and slurry gas flow line
DAY - 4
DAY 5
43
Module
: Maintenance Practice & Inspection (Duration) : 4Weeks 3RD WEEK
DAY - 1
FORENOON AFTERNOON Checking of tubes for any obstruction Procedure of welding of tubes in land test or temperature rise and drop membrane walls and tubes of test. different composition Mechanical portion of governing Checking of over speed ring and system and its maintenance eccentricity pick up for correct operation. Checking of turbovisory instrument Turbine rotor and blade particularly total expansion and maintenance and inspection checks, differential expansion Checking of turbine cylinders for cracks deformation. Checking the rotor position with respect to clearance in HP IP and LP wheel clearance and also thrust bearing and its wear. Checking the condition of babbit metal for scoring pitting, chipping of or lack of bondage between the babbit and the shell. Main oil pump cleaning/flushing of main oil tank, pipes, cleaning of filters oil coolers, mtce. , of jacking oil pumps.
DAY - 2
DAY - 3
DAY - 4
DAY 5
Overhauling of control valves, ESVs Condenser tube maintenance, off and IVs, Maintenance and inspection lead and off load cleaning of oil system turbine oil coolers, procedure Maintenance of condensate side and steam side tubes
44
Module
: Maintenance Practice & Inspection (Duration): 4Weeks 4TH WEEK
DAY - 1
FORENOON Maintenance of main ejectors and starting ejectors Trouble shooting causes remedies, Checking of axial shift indicating system for Clean oil nozzle and strainers.
AFTERNOON Checking of bearing clearances and allowable limits. Checking of cylinders parting surface, for proper matching, its grinding for the purpose.
DAY - 2
Checking of gland and seal strips, their Checking the coupling alignment clearances with allowing limits. of HP IP and LP rotors and generator and their. Setting. Checking and setting of bearings on foundation. Checking of shaft sinking due to I vacuum pulling. Generator Maintenance : A Stator Checking overhang winding, clamp and shields, loss wedges and overheating. Rotor checking of shaft earthing arrangement. hydrogen seal and leakages (purge test) loss wedges, end ring for cracks, overheating. Insulation resistance and winding resistance.
DAY - 3
DAY - 4 DAY 5
Transformer maintenance - insulation HT Switchgear testing - routine testing drying out routine maintenance. and type tests. Motor Insulation checking, terminal Cable jointing, checking, phasing out. motor drying. techniques material and
45
Module : Design Analysis (Duration): 1 week 1st WEEK

FORENOON DAY-1 AFTERNOON
Process designing, Equipment andPressure Vessel design System Design criteria Heat Exchanger Design, RotatingSteam Generator Design equipment design Steam turbine design considerationPiping layout& Piping Design, Design of Ash handling systems and equipment Electrical System Design Design of transformers Design of HT/LT motors Instrumentation System Design
DAY-2
DAY-3
DAY-4 DAY-5
46
Module : Load Dispatch (Duration) : 1 Week DAY - 1 FORENOON AFTERNOON Objective, functions and structure of Location of load dispatch stations Load dispatching stations An area, state and regional and their overview. functions Voltage and frequency control. Trends in design and engineering of load dispatch / systems. MW and AVAR sharing between Load forecasting - Short tern and stations and systems voltage control- long term. Concept of base load and peak load operations - Economic dispatch aspects. Application of computers - DAS, HVDC systems RTUs and SCADA. operation. and SVC
DAY - 2
DAY - 3 DAY - 4 DAY 5
Networking and protocol for data PC based power system study exchange latest developments. package. Visit to load dispatch centre. Group discussion and appraisal.
47
Module : Power Reforms and Regulations (Duration): 1 week 1st WEEK FORENOON AFTERNOON
DAY-1 Power sector reforms-the Indian National electricity policy, energy perspective, Indian Electricity Act conservation act 2003 DAY-2 Power sector reforms in Generation, Transmission DAY-3 CERC-Functions and responsibilities DAY-4 National Tariff policy/ Multi year tariff/ABT DAY-5 Power Trading and Sharing Distribution Reforms Case studies on Open Access systemlong term and short term APDRP/RGGVY Scheme
Case studies on tariff discovery through competitive bidding, quality of power
48
Module
: Control & Instrumentation (Duration) : 2 Weeks 1st WEEK
DAY - 1
FORENOON AFTERNOON Concept and .layout of Control and Pressure Measurement Instrumentation in Thermal Power measuring instruments. Plant. Temperature measurement measuring Instruments.
and
DAY - 2 DAY - 3 DAY - 4 DAY 5
and Flow measurement and measuring Instruments.
Level Measurement and measuring Practical demonstration on pressure Instruments. and flow measurements. Practical demonstration on level and Protection and interlocks of Boiler, temperature measurements. turbine and their auxiliaries. Introduction to auto control. Auto control loops used in thermal stations.
49
Module
: Control & Instrumentation (Duration) : 2 Weeks
DAY - 1
2nd WEEK FORENOON AFTERNOON Turbovisory instrumentation (Parameters Commissioning of control loops limits, Basic concepts of measuring demonstration. devices).
ATRS.
DAY - 2
Visit to control and instrument at control/control stations in the stations.
DAY - 3
Analytical Instrumentation for (Boiler Practical demonstration and Water, Steam, Flue Gas, H2/02/C02). analytical instruments. (Correct : sampling and testing). Introduction to DOC and DAS in Continued ... Thermal Power Station. Introduction to new/latest technology in Group discussion (Performance) Control and Instrumentation in modern thermal power station.
DAY - 4
DAY 5
50
Module
: IT Application in Power Sector & GIS (Duration) : 2 Weeks
1st week
FORENOON DAY - 1
Core of Information Technology (IT) Information Technology Overview Data Structures
AFTERNOON
Development of Computer Technology Communication & Networking Data Processing Techniques
DAY - 2
Hands-on practice on Windows, MS- Computer Networks Resource Office and Typical Application Packages. Sharing Network Topologies Network Hardware Wired vs. 4 Exercises of Hour duration to be done Wireless Networks Wi-fi & in this session. Bluetooth Communications Limitations Client/Server Architecture - LAN, WAN, TCP/IP Network Security.
DAY - 3
Hands-on practice on troubleshooting and general maintenance of Computers and Peripherals. Disk Cleanup Defragmentation Detecting and Clearing Software Virus & Spyware Preventive Maintenance Procedures
Network and Internet based Communications Domains DNS, SLIP, PPP, FDDI - Browsers, Servers, Search Engines Email - File Transfer Protocol (FTP) - Telnet Internet Relay Chat - Instant Messaging Cyber Laws Internet Management - Security Concepts, Information Privacy and Copyright issues Web Hosting Commerce on Internet - Governance on Internet Management Information Systems. Project Management Software MSProject / Primavera.
DAY - 4
Hands-on practice on Windows 2000 or higher network O/S Configuring Workgroups Configuring TCP/IP File/Folder Sharing, Printer Sharing and Internet Sharing.
DAY 5
Hand-on practice on implementing a Network based Management Information System using MS-Access
51
Module
: IT Application in Power Sector & GIS (Duration) : 2 Weeks
2nd week
FORENOON DAY - 1
Concept of Geographical Information System (GIS) Basics of Geography Hardware & Software Requirement
AFTERNOON
Fundamentals of GIS and Mapping Data Visualisation Thematic Map Preparation
DAY - 2
Concepts of Remote Sensing Technology Elements of Remote Sensing (RS) Fundamentals of Photogrammetry Basics of Remote Sensing Electromagnetic Energy
DAY - 3
Concepts of Global Positioning System (GPS) Basics of GPS
Concepts of Global Positioning System (GPS) Working with GPS/DGPS
DAY - 4
Applications of GIS/RS in Power Generation
Applications of GIS/RS in Power Transmission and Distribution
DAY 5
Working with ARC-FM & CYMDIST software
Working on various softwares for distribution network planning and analysis
52
Module
: Environment Management
Duration : 1 week
DAY - 1
FORENOON AFTERNOON Energy and Ecology (Definition of eco Legislation and standards for noise. system, effect of energy on ecology air and water pollution and and concept of green house effect). rehabilitation policy. Environmental Protection Act (EPA)-1986 Water pollution due to thermal power Demonstration of monitoring water station (Water pollutant and their effect quality. on eco-system, waste water treatment, zero discharge concept). Air Pollution caused by coal and oil at. Demonstration of monitoring Air source and due to combustion of coal quality and oil, stack emission ESP etc. Disease caused due to thermal power Environmental impact, assessment plant pollution and other impact. environmental audit. Role of NGOs and media. Appraisal.
DAY - 2
DAY - 3
DAY - 4 DAY 5
Module
: ROJ (Maintenance)
53
Duration:4 Weeks 1ST WEEK FORENOON Boiler Maintenance (Acquaintance with various tools and tackles, Lifting and material handling equipments, consumables and spares). AFTERNOON Turbine stop valves and control valve mtc., Turbine governing system setting, Gland sealing system inspection, Deaerator maintenance. Overhauling of oil system, oil coolers, testing for leakage, flushing of main oil tanks etc
DAY - 1
DAY - 2
Boiler Drum (Drum internal and Turbine Basement/ 0 meter mounting inspection) Firing Floor (condenser tube cleaning, CW (Oil guns, igniter, air, fans, scanner air Pump Maintenance) fans, Air heater, soot blowers, wind box, burner, tilt and coal feeder). Furnace (Boiler tube leakage attending during shut down), edge preparation and welding, post heating etc. , Weld defects testing by NDT method, stress relieving, Coal Mills (Preventive maintenance and overhauling activities, Inspection of classifier blades. Inspection of bull ring segment replacement. Thrust bearing and gear box replacement). ID, FD & PA Fans (Preventive maintenance and overhauling activities, Vibration points). ESP and Ash Handling System (ESP maintenance fly ash maintenance, clinker grinder, bottom ash, slurry pumps etc.) Turbine Maintenance Stores (Acquaintance with various tools and tackles, Lifting and equipments, consumables and spares). Turbine Basement/ 0 meter (BFP maintenance, inspection of bearing, inspection of balancing system, inspection of mechanical system, Hydraulic coupling scoop mechanisms, Adjustments of lube oil pressure and filter cleaning , BFP alignment). HP-LP Hearers Detection of tube leakage and plugging, Alternating water box leakage). HP-LP Heaters (Oil Pumps maintenance Centrifuge bowl cleaning), CT Fans (Preventive maintenance of CT Fans and Gear box, Trays and Nozzle cleaning, Fan blades angle adjustment Water treatment plant and Hydrogen plant (Maintenance of raw water pump and DM pump. Maintenance of H2 for compressors).
DAY - 3
DAY - 4
DAY 5
Module
: ROJ (Maintenance)
54
Duration: 4 Weeks 2nd WEEK FORENOON AFTERNOON Coal Handling Plant (Crusher Exposure to maintenance and maintenance Conveyor maintenance. testing requirements for Drives Feeder maintenance). Coal Handling Plant (Tripper maintenance, Stacker cum Reclaimer maintenance Oil Handling Plant (Oill heaters Exposure to maintenance maintenance, Oil pumps rotary and testing requirements for TSE reciprocating pump etc., Filters/strainers maintenance). Familiarisation of organisation Exposure to maintenance procedures for routine and preventive testing requirements maintenance, breakdown and Temperature Instrument emergency repairs and Instrument lab. set up for calibration and repairs. and
DAY - 1
DAY - 2
DAY - 3
and for
DAY - 4
Exposure to maintenance and testing . Exposure to maintenance and requirements of pressure, flow and testing requirements for DDC, level instruments at site and in lab. DAS etc. Transformers Electric Generator
DAY 5
55
Module
: ROJ (Maintenance) Duration: 4 Weeks 3rd WEEK
DAY - 1 DAY - 2 DAY - 3 DAY - 4 DAY 5
FORENOON Circuit Breakers Electric Motors Electro Static Precipitator Cables Relays and Soleenoid
AFTERNOON . Continue . Continue . Continue
. Continue
56
Module
: ROJ (Maintenance) Duration: 4 Weeks 4th WEEK
FORENOON DAY - 1 DAY - 2 DAY - 3 DAY - 4 DAY 5 Cranes Air Conditioning System HT/LT Supply Circuits AC/DC Lighting Circuits Viva Voce Lift
AFTERNOON Diesel Set HT/LT Supply Circuits Batteries Viva Voce
57
Module
: Visit to Manufacturing Units/TPS Duration: 2 Weeks 1ST WEEK
DAY - 1 DAY - 2 DAY - 3 DAY - 4 DAY 5 DAY - 6
Monday - Travelling Tuesday Visit to BHEL, Hardwar/ Visit to Chandrapur TPS, MSEB Wednesday Travelling Thursday Visit to BHEL, Hyderabdad Friday - Visit to BHEL, Bangalore Saturday - Travelling
Note:- The tour programme can be adjusted by the Institute depending their convenience.
58
Module DAY - 1 DAY - 2 DAY - 3 DAY - 4 DAY 5 DAY - 6
: Visit to Manufacturing Units/TPS (Duration) : 2 Weeks 2ND WEEK
Monday Visit to Neyveli/Vijaywada TPS Tuesday Travelling Wednesday Visit to BHEL, Trichy/ Visit to Trombay, TPS Thursday Visit to BHEL, Bhopal / Visit to Uran Gas Based PS, MSEB Friday - Travelling Saturday Visit to BHEL, Ranipet/ Visit to DESU Gas Turbine Project
59
Module : Simulator (Duration) : 2 Weeks 1ST WEEK FORENOON Introduction to Simulator Centre Pre-checks and system-line up activities for Boiler lit up. Boiler lit up after getting purge complete condition. Pre-checks and system line up Unit start up from cold condition. activities in turbine side (Starting CEP, BEPs and charging condensate/feed water system, Charging turbine oil system, starting oil pumps and putting B/G on operation, Charging Aux. steam and starting vacuum pulling in condenser). Pressure raising in Boiler (Checking HP/LP By pass operation various interlocks and protection, Changing over of auxilaries). Charging steam lines (Operation of Milling Plant Operation. HP/LP By pass, Operation of turbine side drains/vents, M/C Rolling and Synchronisation). AFTERNOON Description of Different Boiler system and boiler lit up.
DAY - 1 DAY - 2
DAY - 3
DAY - 4
DAY 5
Module : Simulator (Duration) : 2 Weeks

60
2 ND WEEK FORENOON Milling Plant Operation and raising pressure as per Boiler load requirements (Operation of second set of auxiliaries and load sharing, Change over of controls from manuals to auto). AFTERNOON Discussion on: (Milling Plant, Burner, Optimum Sec. Air and Drum Level control, Burner Mechanism and attemperators).
DAY - 1
DAY - 2
Raising load in TG (Operation of Unit shutting down procedures. second set of auxiliaries and load sharing, Checking of protections, Changeover of controls from manual to auto). Shutting down unit from full load to 30 Unit start up from hot and warm MW and again raising load to full load conditions. condition. Tripping unit from full load on some Emergency problems in unit protection and start up again from hot (Boiler. Turbine and Generator). condition.
,
DAY - 3
DAY - 4
DAY 5
Operation situation.
unit
under
emergency Summing up programme/Appraisal.
61

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NATIONAL POWER TRAINING INSTITUTE POST GRADUATE DIPLOMA COURSE IN THERMAL POWER PLANT ENGINEERING

No. of Weeks 1 6 2 2 5 2 1 2 1 1 1 1 1 1/2 1 1 1 4 1 1 1 2 2 1 4 2 2 1/2 1 1 52

100 100 100 100

150 150 150 150

150 150 100 50 1050

100 100 100

150 150 150

150 150 50 100

RULES AND REGULATION

ADMISSION AND ELIGIBILITY

FIRST SEMESTER PGDC IN TPPE

Module : General Introduction (Duration): week

Module : Industrial Safety (Duration): week

Module : Power Plant Familiarization (Duration): 6 week

Steam Separation theory ( Boiler Drum & its internals)

Module : Power Plant Familiarization (Duration): 6 week 2 ND WEEK

Module : Power Plant Familiarization (Duration): 6 week 3RDWEEK

AFTERNOON Audio Visual Session (FSSS)

Boiler Feed Pump (Function of BFP Constructional details)

: Power Plant Familiarization (Duration): 6 Weeks

: Power Plant Familiarization (Duration) : 6 Weeks

: Power Plant Familiarization (Duration) : 6 Weeks

: Scheme Briefing & Tracing (Duration) : 2 Weeks 1ST

: Power Plant Operation (Duration) : 2 Weeks 1ST WEEK

: Power Plant Operation (Duration): 2 Weeks

DAY - 1 DAY - 2 DAY - 3 DAY - 4

: ROJ (OPERATION) (Duration): 5 Weeks

: Erection, Commissioning & Construction Management

: Erection, Commissioning & Construction Management (Duration) : 2 Week Construction Management

: Power Plant Performance and Efficiency Calculation (Duration) : 1 Week

: Advanced Steam Generation Technology- Supercritical and FBC (Duration) : 1 Week

: Business Communication & Personality Development (Duration) : 1 Weeks 1ST WEEK

SECOND SEMESTER PGDC IN TPPE

: Power Plant Protection (Duration) : 1 Week

Module : Energy Audit (Duration): week

: Maintenance Planning & Cost Control (Duration) : 1 Week

: Nuclear Power Plant Familiarization (Duration) : 1 Weeks 1ST WEEK

Energy Sector Reforms, Regulations Environment and RE

Solar thermal power systems

Direct energy Conversation - Solar Photovoltaic, Fuel Cells.

Biomass Energy Systems.

Introduction of small, mini and hydro power generations

Basic features of hydro Turbines

Hydrology and estimation of water potential

Site selection and Layout of Hydro power plants

Description of Hydro Interlocks and protection

: Maintenance Practice & Inspection (Duration) : 4Weeks 1ST WEEK

: Maintenance Practice & Inspection (Duration): 4Weeks 2ND WEEK

: Maintenance Practice & Inspection (Duration) : 4Weeks 3RD WEEK

: Maintenance Practice & Inspection (Duration): 4Weeks 4TH WEEK

Module : Design Analysis (Duration): 1 week 1st WEEK

DAY - 3 DAY - 4 DAY 5

Case studies on tariff discovery through competitive bidding, quality of power

: Control & Instrumentation (Duration) : 2 Weeks 1st WEEK

DAY - 2 DAY - 3 DAY - 4 DAY 5

and Flow measurement and measuring Instruments.

: Control & Instrumentation (Duration) : 2 Weeks

Visit to control and instrument at control/control stations in the stations.

: IT Application in Power Sector & GIS (Duration) : 2 Weeks

: IT Application in Power Sector & GIS (Duration) : 2 Weeks

Concepts of Global Positioning System (GPS) Basics of GPS

Concepts of Global Positioning System (GPS) Working with GPS/DGPS

Applications of GIS/RS in Power Generation

Applications of GIS/RS in Power Transmission and Distribution