Thermal Power Plant

NORTHERN POWER GENERATION COMPANY
LIMITED
GENCO-III
THERMAL POWER STATION MUZAFFARGARH
INTERNSHIP REPORT
1st August 2019 – 1st September 2019
Submitted By:
Muhammad Qasim
CIIT/FA17-BME-076/SWL
Submitted To:
Internship Supervisor
Engr. Muhammad Shahid
COMSATS University Islamabad Sahiwal

Campus
Department of MECHANICAL ENGINEERING
Internship Report 2019 Muzaffargarh Thermal Power
Plant
Preface
Theoretical knowledge is not so important without a combination of exercise. It is part of their
academic curriculum to complete internships of BS students (mechanical engineering) in various
technical subjects to give students the opportunity to acquire practical and procedural
knowledge. As a sub-filament of Bs (Mechanical Engineering), the author of this report was also
given the task of drafting the semester report. The topic was "(GENCO-III) Northern Power
Generation Company Limited". Adapting to such a large organization was not an easy task, but
by the grace of Allah it helps my internship in an advantageous way and I learned a lot about the
generational enterprise in general. This report is a complete summary of my rigorous studies that
I conducted over a one-month period at the generation company. I studied and monitored the
operation of the company and did everything possible to keep pace with all dimensions of the
production company. It was a great experience to work there and to learn the difficulties. I thank
everyone who helped me in one way or another, and guided me in presenting ways to prepare
and compile this report.
1
Plant
Acknowledgment
We thank ALMIGHTY ALLAH, who gave me the strength to think, plan and act in accordance
with the principles that allow us to do my internship.
It is a literary tradition to recognize the contribution and help of different people and
organizations to complete an internship, but in fact some words cannot express our gratitude for
the various helping hands. It is very difficult to appreciate each one for their contribution,
without these people it would be difficult for us to complete this internship successfully.
In addition, we would like to thank our internship director "Ing. Muhammad Shahid AME
Thermal Power Plant Muzaffargarh", who took the time to listen to us, guide us and continue to
find us the right way and make it possible, despite the extraordinary attention to their tasks.
Working as an industrial coach in his esteemed organization and extending it during training.
Internship Supervisor
Eng. Muhammad Shahid (AME)
Thermal Power Station Muzaffargarh
2
Plant
DEDICATION
At the beginning, he dedicated this work to Almighty Allah, without his compassion and
compassion I could not do this work. The almighty ALLAH gave me strength and confidence to
complete my internship, and also the HOLY PROPHET HAZARAT MUHAMMAD (peace be
upon him), who is a light For humanity I dedicate this work also to my adorable parents with
deep gratitude, their love and Prayers have always been a source of strength for me.
I would also like to mention my father and mother, who have always been a source of inspiration
to me, assisting me in every one of my decisions, and allowing me to make mistakes, as mistakes
made the man I am today.
3
Plant
EXECUTIVE SUMMARY
In accordance with the requirements for an internship, I spent a month at GENCO from 01-08-
2019 to 01-09-2019. That was a lot of study time for me. This internship report is about the
Muzaffargarh thermal power plant, also called GENCO-III. In GENCO-III there are a total of 6
units in which Phase I consists of 210 MW each and Phase II consists of 2 units of 210 MW each
and a separate unit, Unit 320, with a capacity of 320 MW . Then a total of 1370 MW of
GENCO-III. The installed generation is an oven oil production consisting of a steam turbine and
a water pipe boiler. Different types of generator and transformer protection are discussed in this
Repot. The circuit breakers and their types and relays will be briefly explained, as well as the
role of the instrument transformer. The important maneuvering yard is detailed. Later, all kinds
of engines come to light.
In this report, I gave an introductory story of GENCO-III. I have spent many days in various
sections of Division No. 4, including boiler, turbine, pumping and chemical stations. In this
report I describe the work and functions of these departments. In this report, I did a SWOT
analysis. There are also some recommendations at the end.
4
Plant
Table of Contents
1. Plant Layout ………………………………………………………………08
2. Fuel Oil Tanks…………………………………………………………….09
2.1 Furnace Oil Flow Cycle ………………………………………………09
3. Mission Statement ………………………………………………………..10
3.1 Background …………………………………………………………………..10

3.2 Introduction……………………………………………………………….10-11
4. Capacity ......................................................................................................12
4.1 Phase-1……………………………………………………………………….12
4.2 Phase-2………………………………………………………………………..12
4.3 Some Key Facts………………………………………………………………12
Week-1
5. Boiler ………………………………………………………………………13
5.1 Water Tube Boiler ……………………………………………………………..13

5.2 Major Components of Water Tube Boiler………………………………………13
5.3 Working of Water Tube Boiler………………………………………………….14
5.4 Balanced Draft Boiler……………………………………………………………14
5.5 Induced Draft Fan…………………………………………………………………15
5.6 Forced Draft Fan………………………………………………………………….15
5.7 Gas Recirculation Fan…………………………………………………………….15
5.8 Super Heater………………………………………………………………………..15
5.9 Soot Blower……………………………………………………………………….16
5.10 Combustion Cycle………………………………………………………………..16
5.11 Deaerator…………………………………………………………….....................17
5.12 Boiler Feed Water Tank…………………………………………………………17
5
Plant
5.13 Feed Water Pump……………………………………………………………….17
Week-2
6. Cooling Tower………………………………………………………………18
6.1 Working…………………………………………………………………………..18
6.2 Cross Flow Cooling……………………………………………………………….19
6.3 Circulating Water Pump…………………………………………………………..19
7. Chemical Treatment Plant…………………………………………………….20
7.1 External Treatment………………………………………………………………..20

7.2 Internal Treatment…………………………………………………………………20
7.3 Water Purification System…………………………………………………………20
7.4 Mechanical Filters………………………………………………..………………20
7.5 Cation Filter 1……………………………………………………………………20
7.6 De-gassifier……………………………………………………………………….21
7.7 Anoin Filter………………………………………………………………………..21
7.8 Cation Filter 2……………………………………………………………………..21
7.9 Mixed Bed Filter………………………………………………………………….21
7.10 Demineralized Water Tank………………………………………………………..21
8. Valve………………………………………………………………………...22
8.1 Gate Valve……………………………………………………………………….22

8.2 Globe Valve……………………………………………………………………….22
8.3 Pressure Relief Valve………………………………………………………………23
8.4 Pressure Safety Valve………………………………………………………………23
Week-3
9. Steam Turbine…………………………………………………………………24
10. Rankine Cycle………………………………………………………………..24
6
Plant
11. Components of Steam Turbine………………………………………………25
11.1 Rotor……………………………………………………………………………..25
11.2 Steam Chest and Casing…………………………………………………………25
11.3 Casing Sealing Glands…………………………………………………………..25
11.4 Over-speed Trip System…………………………………………………………25
11.5 Governor System………………………………………………………………..25
12. Stages of Steam Turbine……………………………………………………26
12.1 HP Turbine…………………………………………………………………..26
12.2 IP Turbine…………………………………………………………………….26
12.3 LP Turbine…………………………………………………………………..26
13. Steam Turbine Generator………………………………………………..26
14. How It Works? .............................................................................................26
15. Generator Cooling System……………………………………………….27
16. Jacking Oil Pump………………………………………………………...27
17. Centrifugal Pump…………………………………………………………28
18. Condenser…………………………………………………………………28
19. Condensate Pump…………………………………………………………29
20. LP Heaters………………………………………………………………..29
21. HP Heaters………………………………….…………………………….29
Week-4
22. Couplings………………………………………………………………...30
23. Types of Coupling……………………………………………………….30
23.1 Rigid Coupling………….………………………………………31

23.2 Flexible Coupling…………….………………………………32-33
7
Plant
24. Bearing…………………………………………………………………..34
24.1 On Basis of Friction……………………………………………..34

24.1.1 Friction Bearing……………………………………..34-35
24.2.2 Anti- Friction Bearing……………………………….35-38
24.2 On Basis of Load……………………………………………..38-39
8
Plant
1. Plant Layout
9
Plant
2. Fuel Oil Tanks:

From the settling area the furnace oil is filled into the storage tanks. From there it is fed to the
burners of the boiler oven after sufficient heating. In general, a storage tank is referred to as a
service tank, from which the units fuel oil is supplied. The furnace oil is first filled into the main
tank and then into the service tank via circulation pumps (CPR). The oil in the tanks is kept
warm at a temperature of 75-80 ° C. There are a total of 06 storage tanks for furnace oil, each
with a volume of 20,000 m3, so that 20,000 tonnes can be stored. There are two diesel tanks with
a capacity of 1000 tons each.
2.1. Furnace Oil Flow Cycle:
Figure 1: Furnace Oil Flow Cycle
10
Plant
3. Mission statement:
Our mission is to provide our customers with the certainty of energy, with first class quality and
commitment to satisfaction, while striving for excellence.
3.1 Background:
Northern Power Generation Company Limited owns and operates thermal power plants in
Muzaffargarh, Multan and Faisalabad. The installed capacity of the generation capacity is 1921
MW, which has decreased over the years to a reliable capacity of 1169 MW, which limits the
company's operational and financial performance due to internal and external factors. The
company has achieved a negative result, which has jeopardized sustainability.
The Government of Pakistan has set itself the objective of addressing the problems of the
country's energy sector through the implementation of the energy sector reform program. Under
the program, GENCOs, including NPGCLs, had to develop and implement business plans to
respond effectively to limitations and barriers to satisfactory performance.
3.2 Introduction:
This thermal power plant is located in the Muzaffargarh district of the Multan division. In 1985,
Ghulam Ishaq Khan concluded an agreement with Russia on the construction of the power plant.
This project was originally documented for Multan. But for certain reasons such as farmland,
costs, etc., this project was relocated to Muzaffargarh called Multan-II. Initially, three units
called Phas-1 were founded in Muzaffargarh. These units are also called Russian units. These
units work with oil and gas. Every 210MW of power. China is configuring its units to meet
electricity needs. These units also have 210 MW. China also founded a unit called # 4 witches
with a capacity of 320 MW. Unit # 4 is fully computerized. All functionality is handled by
computer programs. This organization employs about 1500 people, both technical and non-
technical. For this project, the Muzaffargarh economic district was selected. Other reasons for
this location are that there is no spa in this area. At that time, the area like the Multan Division
and D.G. Khan was approximately in central Pakistan. The location can be chosen for security
reasons in war conditions.
11
Plant
The Water and Energy Development Authority of Pakistan (WAPDA) is an integrated utility in
Pakistan. WAPDA is responsible for the development of the hydroelectric and water sector
project in Pakistan. WAPDA operates through water wings and is responsible for the generation,
transmission and distribution of energy. In addition, it manages the irrigation, water supply and
drainage systems of the country. In addition, it is also responsible for the prevention of water
residues and the recovery of water and saline land residues.
The Water and Energy Development Authority of Pakistan (WAPDA) was established in
February 1958 by a law of the Parliament for the rapid and integrated development and
conservation of the country's water and energy resources. Under the Act, which was amended in
March 1959 to transfer the existing Electricity Division of the Federation Units to WAPDA, the
tasks of research, planning and implementation of projects and projects were transferred to:
• • Generation, transmission and distribution.

• • Irrigation, water supply and drainage.
• • Preventing water retention and recovering saline land.
• • Food inspection and inland navigation.
As part of subsequent developments, the "1994 Energy Policy", the creation of thermal
power generation projects has been transferred to the private sector. At present 13 companies
work under WAPDA.
• These are:
• • National Transmission and Distribution (NTDC)
• • Four thermal energy companies (GENCO)
• • eight sales companies (discs)
12
Plant
Figure 2: Muzaffargarh Thermal Power Station
4. Capacity
“Capacity is the maximum rate of output for a facility”. The facility can be a workstation or an
entire organization.
There are two phases working at thermal power station Muzaffargarh.
4.1 PHASE-1:
In phase one there are three units of capacity 210MW. This phase was established by Russia also
called Russia phase.
13
Plant
4.2 PHASE-2:
In phase two there are two units of capacity 210MW and one unit of capacity 320MW.
The phase-1 can produce 15120000 units/24 hrs.
So, the total capacity of both two phase is 48000000 units/24 hrs. But this is situation when all
the units are working with their full capacity. But there is little situation
When this type of occurrence. But they utilize their capacity according to the requirement. All
the decisions about the utilization are done at higher level. NPCC Islamabad gives all the
instruction about the utilization. The reason is that all the thermal houses in Pakistan are
connected just a ring topology (the term in networking). When sufficient amount of water is
available the more concentration are given to produce Hydroelectricity because this source of
electricity are much cheap than thermal electricity.
4.3 Some Key Facts:

Unit Installed Working Constructed By Construction
Capacity Capacity Date
1 210 MW 175 MW Russia Sep. 1993
2 210 MW 170 MW Russia March 1994
3 210 MW 170 MW Russia Feb. 1995
4 320 MW 280 MW China Dec. 1996
5 200 MW 165 MW China Dec. 1995
6 200 MW 165 MW China Dec. 1995
Total 1350 MW 1125 MW
Table 1: Plant Installed Capacity
14
Plant
Week 1 -Boiler
5. Boiler
A vessel that heats the water and converts it into pressurized steam (Saturated Steam).
5.1 Water Tube Boiler

A water tube boiler can be defined as a Steam boiler in which the flow of water in the tubes, as
well as hot gases, encloses the tubes (Thousands of tubes that form a membrane inside the
boiler). Not like fire tube boilers, this boiler attains high-pressures, as well as high-steam
capabilities, can be achieved. This is because of condensed tangential pressure on tubes which is
known as hoop stress.
Figure 3: Water Tube Boiler
15
Plant
5.2 Major Components of Water Tube Boiler:

The water tube boiler can be built with boiler shell, burner, mud drum or mud ring, furnace,
safety valve, strainer, sight glass, feed check valve, steam stop valve, etc.
• Boiler Shell: This shell is the external cylindrical part of a pressure container.
• Boiler Drum: This is a cylindrical formed space at the base of the water space. The
impurities like mud, sediment, and others will be gathered.
• Strainer: This is a type of device as a filter to hold solid elements letting a fluid to
supply.
• Boiler: This is a surrounded space offered for the fuel combustion.
• Burner: This is one type of device for the beginning of air and fuel into a boiler at the
preferred velocity.
5.3 Working of Water Tube Boiler:
The two drums are associated via two tubes such as down comer and riser. At first, the water is
supplied into the steam type drum with the help of a water pump. Whenever the fuel is burned,
then hot gases will be generated that are permitted to supply in the shell part of the boiler. The
hot gases which are produced by the fuel will replace heat by the water; the water gets changed
into steam. Because, the water temperature increases, the concentration will increase
automatically. Clearly, the concentration of steam will be lesser than the water. Thus, in the
steam drum, the water, as well as steam, gets divided obviously due to variation in concentration.
The flow of hot water at the base of the steam drum will be supplied into header via down comer
tube as well as to heat the water in the header.
5.4 Balanced Draft Boiler:
In Balanced Draft Boilers, Furnaces equipped with both an FD (Forced Draft) and ID (Induced
Draft) fans. In balanced draft systems, the forced and induced draft fans work together to move
combustion air and flue gases through the furnace. The FD fan is used to regulate the combustion
airflow and the ID fan is used to regulate furnace pressure. Balanced draft furnaces are typically
operated slightly below atmospheric pressure.
16
Plant
Figure 4: Balanced Draft System
5.5 Induced Draft Fan:
An induced draft fan draws the gases through the flue ducting and the combustion air into the
furnace making high stacks unnecessary. Control is accomplished by regulating the fan speed or
damper operation.
5.6 Forced Draft Fan:
A forced draft furnace uses a fan or blower to force combustion air through the system. Control
is accomplished by regulating the fan speed or damper operation. This type of furnace is
operated slightly above atmospheric pressure. Forced draft furnace must be airtight to prevent
leakage of flue gases into surrounding area.
5.7 Gas Recirculation Fan:
GRC fan forced the exhaust back into the burner so that complete combustion is achieved, and
the un-burnt fuel or gases is removed from the exhaust.
5.8 Superheater:
The Steam Superheater is a coil type heat exchanger which is used to produce superheated
steam or to convert the wet steam to dry steam, generated by a boiler. It is different from
17
Plant
a boiler in a way that, boiler utilizes both sensible heat as well as latent heat to convert water into
steam while super heater utilizes only sensible heat to superheat the steam in order to increase its
enthalpy.
Figure 5: Super Heater
5.9 Soot Blower:

Soot blowers is mechanical device automatically controlled to deliver intermittent jet of
compressed steam to clean ash, soot, slag from heat absorbing surfaces by blowing on the
surface. Soot blower is used eliminate slag, so maintain efficient flue gas temperatures and
generally promote more desirable operating conditions.
Figure 6: Soot Blower
18
Plant
5.10 Combustion Cycle:
Figure 7: Combustion CycEle in Boiler
5.11 Deaerator:
A deaerator is a device that is widely used for the removal of oxygen and other dissolved gases
from the feed water to steam-generating boilers. In particular, dissolved oxygen in boiler feed
waters will cause serious corrosion damage in steam systems by attaching to the walls of metal
piping and other metallic equipment and forming oxides (rust). Dissolved carbon dioxide
combines with water to form carbonic acid that causes further corrosion. Most deaerators are
designed to remove oxygen down to levels of 7 ppb by weight (0.005 cm³/L) or less as well as
essentially eliminating carbon dioxide.
19
Plant
Figure 8: Deaerator
5.12 Boiler Feed Water Tank:

It is an essential part of boiler operations. The feed water is put in to the steam drum from a feed
pump. In the steam drum the feed water is then turned into steam from the heat. After the steam
is used it is then dumped to the main condenser. From the condenser it is then pumped to the
deaerated feed tank. From this tank it then goes back to the steam drum to complete its cycle.
The feed water is never open to the atmosphere.
5.13 Feed Water Pump:

A boiler feed water pump is a specific type of pump used to pump feed water into a steam boiler.
Feed water pump is high pressure centrifugal pump having 11 stages. Inlet pressure of water is
8kg/cm2 and outlet pressure is up to 190kg/cm2.
20
Plant
Week 2 –Cooling Tower and Chemical Plant

6. Cooling Tower:
Cooling towers are a special type of heat exchanger that allows water and air to come in contact
with each other to lower the temperature of the hot water. During this process, small volumes of
water evaporate, lowering the temperature of the water that's being circulated throughout the
cooling tower. In a short summary, a cooling tower cools down water that gets over heated by
industrial equipment and processes.
Figure 9: Cooling Tower

For Unit (1,2,3),
Total Cooling Tower 6 Total Fan 48
For Each Unit 2 for Each Tower 8
6.2 Working:
The hot water is usually caused by air conditioning condensers or other industrial processes. That
water is pumped through pipes directly into the cooling tower. Cooling tower nozzles are used to
spray the water onto to the "fill media", which slows the water flow down and exposes the
maximum amount of water surface area possible for the best air-water contact. The water is
exposed to air as it flows throughout the cooling tower. The air is being pulled by a motor-driven
electric "cooling tower fan". When the air and water come together, a small volume of water
evaporates, creating an action of cooling. The colder water gets pumped back to the
process/equipment that absorbs heat or the condenser.
21
Plant
6.3 Cross flow Cooling:

In Cross flow cooling the water vertically flows through the fill media while the air horizontally
flows across the falling water. That's why they call it "cross flow" because the air and water cross
paths or flows. Because of the crossing of flows, the air doesn't need to pass through the
distribution system. This permits the use of hot water flow via gravity and distribution basins on
the top of the tower right above the fill media. The basins are a standard of Cross flow cooling
towers and are applied on all units.
Figure 10: Cross Flow Cooling
6.4 Circulating Water Pump:
This is the pump to send cooling water to the condenser. It receives water from for bay. Before
sending water to the condenser water is passed through a screen filter to remove impurities
.circulating water pump is centrifugal pump having vertical shaft.
Type Y1600-12/2150
Rated Voltage 6.6 KV
Rated Current 182 A
Rated Speed 372 RPM
Rated Power 1600 KW
Rated Frequency 60 Hz
Capacity 16000 m3/H
Power factor 0.9
Table 2: CW Pump Specifications
22
Plant
The motor of pump is oil cooled and air cooled .Stator winding connection is Y. the rated
frequency is 50
Hz and no. phases are 3. Water from the circulating water pump is passed through these pipes it
consist of ideal flow gate valve during start of pump this valve remain open until non return
valve is not fully open.
As non-return valve fully open this valve will be closed. Vent valve is used to remove bubbles
and air from pipe line this is low pressure and high discharge flow pump.
7. Chemical Water Treatment:

There are two ways of chemical water treatment.
7.1 External Treatment:
External treatment is the reduction or removal of impurities from water outside the boiler. In
general, external treatment is used when the amount of one or more of the feed water impurities
is too high to be tolerated by the boiler system in question.
7.2 Internal Treatment:

Internal treatment is the conditioning of impurities within the boiler system. The reactions occur
either in the feed lines or in the boiler proper. Internal treatment may be used alone or in
conjunction with external treatment. Its purpose is to properly react with feed water hardness,
condition sludge, scavenge oxygen and prevent boiler water foaming.
7.3 Water Purification System:

For the making of steam and for the cooling of generators only the pure H2O water is used
because, impure particles in this water causes,
• Vibrations in the turbines and damage its blades.

• Corrosion inside the pipes.
• Electrical conductivity between the generator windings.
23
Plant
To purify the water from makeup tank there is a water treatment plant, where this water passes
through different stages to remove its impurities. The block diagram of this plant is given below.
The raw water in this plant passes from 6 different stages which are:
• Mechanical Filters
• 1stStage of Cation Filter
• De-Gasifier
• Anion Filter
• 2nd Stage of Anion Filter
• Mixed Bed Filter
7.4 Mechanical Filters:

First of all, raw water enters in these filters. Four filters are installed for this purpose, in which
two of them are functional while other two are for stand-by use. Each tank has the capacity of
45T/h.
7.5 Cation Filter 1:

Clarify water passed through cation bed exchanger –ve charge disappear is called cation. To
removing the cation salts like ( Ca+2, Mg+2, Na+1 ),this water passes through cation filter,
where it interacts with hydrogen ions H+. These hydrogen ions replace the other cations from
their salts and removed in this stage.
7.6 De-Gasifier:
De- gasifier or de- carbonizes are used to remove CO2 gas from the water. For this purpose there
are two main chambers where water is showering from the top and air is entered form the bottom
by fans. This air interacts with the carbon ions in water and makes CO2 gas, which moves out
from the top side of chamber. And the water collected in the storage tank, located below the
chamber.
7.7 Anion Filter:
Calorify water is passed through anion bed exchanger +ve charge disappear. Water is sent to
anion filter form decarbonized water tank, using pumps. There are four filters in which one is
used and other are for backup. Each filter has capacity of 90T/h. Na OH is introduced in water to
remove silica and other anions.
24
Plant
7.8 Cation Filter 2:

If any amount of cations remain in water even after cation filter, these filters remove those
cations. 98% pure H2SO4 is added in this filter to provide more H+ ions.
7.9 Mixed Bed Filter:

This is the last stage of water treatment procedure. It has the capability to remove both cations
and anions from water. They have a very good efficiency.
7.10 Demineralized Water Tank:

After passing through the filters, water is sent to the demi water storage tank. This water has no
hardness and all other minerals values in tolerable ranges. Three tanks are available, each with
the capacity to store 2000 metric ton water. This water is supplied through pumps to the makeup
connection after hot well to fulfill the demand of unit.
Figure 11: Water Treatment Plant
8. Valve:
A device for controlling the passage of fluid or air through a pipe, duct, etc. especially an
automatic device allowing movement in one direction only.
25
Plant
Types of Valve:
8.1 Gate Valve:
Gate valves (also known as knife valves or slide valves) are linear motion valves in which a flat
closure element slides into the flow stream to provide shut-off. These valves are used to control
high pressure and also prevent leakage. A drawback of this valve is it operates slowly.
Figure 12: Gate Valve
8.2 Globe Valve:

A Globe valves is a linear motion valve and are primarily designed to stop, start and regulate
flow. The disk of a Globe valve can be totally removed from the flow path or it can completely
close the flow path.
These valves operate quickly.
26
Plant
Figure 13: Globe Valve
8.3 Pressure Relief Valve:

It is the term used to describe relief device on a liquid filled vessel. For such a valve the opening
is proportional to increase in the vessel pressure. Hence the opening of valve is not sudden, but
gradual if the pressure is increased gradually. It does not release the liquid in to the atmosphere.
Figure 14: Pressure Relief Valve
27
Plant
8.4 Pressure Safety Valve:

It is the term used to describe relief device on a compressible fluid or gas filled vessel. For such a
valve the opening is sudden. When the set pressure of the valve is reached, the valve opens
almost fully. It releases the liquid in to the atmosphere.
Figure 15: Pressure Safety Valve
28
Plant
Week 3 –Turbine Section

9. Steam Turbine:
A Steam Turbine is a mechanical device that extracts thermal energy from pressurized steam and
transforms it into mechanical work. Because the turbine generates rotary motion, it is
particularly suited to driving electrical generators. Steam Turbine works on Rankine Power
Cycle.
10. Rankine Cycle:

The Rankine cycle is the fundamental operating cycle of all power plants where an operating
fluid is continuously evaporated and condensed. The selection of operating fluid depends mainly
on the available temperature range.
• Isobaric Heat Transfer. High pressure liquid enters the boiler from the feed pump (1) and
is heated to the saturation temperature (2). Further addition of energy causes evaporation
of the liquid until it is fully converted to saturated steam (3).
• Isentropic Expansion. The vapor is expanded in the turbine, thus producing work which
may be converted to electricity. In practice, the expansion is limited by the temperature of
the cooling medium and by the erosion of the turbine blades by liquid entrainment in the
vapor stream as the process moves further into the two-phase region. Exit vapor qualities
should be greater than 90%.
• Isobaric Heat Rejection. The vapor-liquid mixture leaving the turbine (4) is condensed at
low pressure, usually in a surface condenser using cooling water. In well designed and
maintained condensers, the pressure of the vapor is well below atmospheric pressure,
approaching the saturation pressure of the operating fluid at the cooling water
temperature.
• Isentropic Compression. The pressure of the condensate is raised in the feed pump.
Because of the low specific volume of liquids, the pump work is relatively small and
often neglected in thermodynamic calculations.
29
Plant
Figure 16: Rankine Cycle
11. Components of a Steam Turbine:

1. 11.1 Rotor: Consists of shaft and disk assemblies with buckets. The shaft extends beyond
the casing through the bearing cases. One end of the shaft is used for coupling to the
driven pump. The other end of the shaft serves the speed governor and the over speed trip
system.
2. 11.2 Steam Chest and Casing: Connected to higher pressure steam supply line and the
low pressure steam exhaust line respectively. The steam chest connected to casing,
houses the governor valve and the over speed trip valve. The casing contains the rotor
and nozzles through which the steam is expanded and directed against the rotating
buckets.
3. 11.3 Casing Sealing Glands: Seal the casing and the shaft. Spring backed segmental
carbon rings used for this and supplemented by a spring backed labyrinth section for
higher exhaust-steam.
4. 11.4 Over Speed Trip System: The trip mechanism acts independently of the governor
controlled system and closes the trip valve to stop the flow of steam to the turbine in the
event of over speed condition. Consists of a spring-loaded pin or weight mounted in the
turbine shaft on a collar, a quick-closing valve which is separate from the governor valve
and interconnecting linkage. The centrifugal force created by rotation of the pin in the
turbine shaft exceeds the spring loading at a preset speed. The resultant movement of the
trip pin causes knife-edges in the linkage to separate and permit the spring loaded trip
valve to close. Over speed governors is arranged to trip at 10 percent over normal speed
actuating a quick closing stop valve to shut off the steam supply to the turbine.
5. 11.5 Governor System: Governor Systems are speed-sensitive control systems that are
integral with the steam turbine. The turbine speed is controlled by varying the steam flow
30
Plant
through the turbine by positioning the governor valve. Consists of spring-opposed

rotating weights, a steam valve, and an interconnecting linkage or servo motor system.
The governor sense turbine shaft speed through direct connection, worm/worm wheel, or
magnetic impulse from a gear. The turbine speed is compared to some predetermined set
point and the governor output signal to a servo motor.
Figure 17: Steam Turbine
12. Stages of Turbine:

Usually, there are 3 stages. > HP Stage > IP Stage > LP Stage. Each stage consists of one ring of
fixed blades, which act as nozzles, and one ring of moving blades.
1. 12.1 HP (High Pressure) Turbine: High pressure (182 bars) and High temp. (547
Degrees) of steam at inlet. The steam has 300 Degrees temp. and 34 bars at outlet.
2. 12.2 IP (Intermediate Pressure) Turbine: From HP turbine the steam goes to a reheater
and the temp. Is raised up to 547 Degrees and 29 bars pressure is kept to avoid the back
pressure of steam in HP turbine.
3. 12.3 LP (Low Pressure): Turbine: From IP turbine the steam goes to LP turbine without
reheating because there is no need of further raise in temp. and pressure.
31
Plant
Figure 18: Multistage Steam Turbines
13. Steam Turbine Generator:

A steam turbine generator is a device that uses steam to rotate a turbine generator to produce
electricity. Steam turbines use water that is heated to extremely high temperatures and converted
into steam to rotate the blades of a turbine, in order to create mechanical or rotational
energy. This rotational energy caused by the high pressured steam turbine is used to generate
electricity in an attached generator.
14. How It Works?

It is impossible to set a magnet on high scales generators so; an exciter is used to create an
artificial magnet in the generator, Since the generator load current is generally much higher than
the field current, it is usually desirable to use the rotor to create the field and to take the power
off the generator from the stator to minimize the load on the slip rings. The rotating armature
cuts the magnetic field of magnet and generates an EFM that in fact generates electricity. The
instead of carbon brushes, diodes are used in the 320 MW Steam Turbine in muzaffargarh
thermal power plant to control the flow of electricity.
15. Cooling of Generator:

To avoid overheating, special cooling precautions must be taken and two forms of cooling are
usually employed simultaneously. Cooling water is circulated through copper bars in the stator
windings and hydrogen is passed through the generator casing. Hydrogen has the advantages that
32
Plant
its density is only about 7% of the density of air resulting in fewer wind age losses due to the
rotor churning up the air in the machine and its thermal capacity is 10 times that of air giving it
superior heat removal capability.
Figure 19: Steam Turbine Generator
16. Jacking Oil Pump:

Jacking Oil Pump is used for the lubrication of shaft before initiation; the jacking oil
pumps deliver oil at around 300 bar to the individual bearings. The pumps used are motor-
driven positive displacement (Such pumps has suction section on the Inlet and expanding section
on the outlet) and either multi-plunger pumps or two-shaft gear pumps.
33
Plant
Figure 20: Jacking Oil Pump
17. Centrifugal Pump:

A centrifugal pump is a mechanical device designed to move a fluid by means of the transfer of
rotational energy from one or more driven rotors, called impellers. Fluid enters the rapidly
rotating impeller along its axis and is cast out by centrifugal force along its circumference
through the impeller's vane tips.
34
Plant
Figure 21: Centrifugal Pump and its Components
18. Condenser:
The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be
pumped. In TPS Muzaffargarh surface type condenser is used. The surface condenser is a shell
and tube heat exchanger in which cooling water is circulated through the tubes. The exhaust
steam from the low pressure turbine enters the shell where it is cooled and converted to
condensate e (water). The cooling water is return to the cooling tower and condensate is
collected in hot well.
Figure 22: Surface Condenser
35
Plant
This extracts the greatest amount of energy from the steam to maximize the power output of the
turbine. The steam, at this low pressure (vacuum) condenses at 65°C. The condenser operates
under high vacuum which occurs due to the condensing of the steam. (This causes a huge
volume decrease in that the water, When converted to steam expands by 1,800 times. When
condensing, it therefore occupies a volume 1,800 times LESS as water). The water formed is
pumped back to the Boilers for re-use. The Cooling towers don't cool this water as its treated
water specifically used for steam generation. A separate Cooling Water System is used for the
surface condensers and other heat exchange (cooling) systems throughout the Power Station. It's
this water that is cooled by the towers and is also recycled from the tower collecting basin to the
Cooling Water distribution pumps.
19. Condensate Pump:

Condensate pump receive condensate from the hot well and transfer to steam air ejector. Pressure
of condensate rises in condensate pump up to 15 kg/cm2. The total number of condensate pumps
3.
20. L.P Heaters:

L.P Heaters are used to increase the temperature of condensate. Temperature of condensate is
increased by steam bleedings. Bleedings are extracted from different stages of turbine as
described below:
Stage No. Heater No:

25 of (L.P Turbine) is connected to L.P Heater 1
23 of (I.P Turbine) is connected to L.P Heater 2
21. H.P Heaters:

H.P Heaters are placed between feed water pump and economizer. These are used to increase the
temperature of feed water. Bleedings are extracted from different stages of turbine as described
below:
Stage No. Heater No:

15 of (I.P Turbine) H.P Heater 5
12 of (H.P Turbine) H.P Heater 6
09 of (H.P Turbine) H.P Heater 7
36
Plant
Week 4 –Couplings and Bearings

22. Coupling:
Couplings are mechanical elements that ‘couples’ two drive elements which enables motion to
be transferred from one element to another. The drive elements are normally shafts.
23. Types of Couplings:

23.1 Rigid Coupling: Rigid Couplings are mainly used in areas where the two shafts are coaxial
to each other. Rigid Couplings are further classified as,
• Sleeve or Muff Coupling: This is the basic type of coupling. This consists of a
pipe whose bore is finished to the required tolerance based on the shaft size.
Based on the usage of the coupling a keyway in made in the bore in order to
transmit the torque by means of the key. Two threaded holes are provided in order
to lock the coupling in position.
Figure 23: Muff or Sleeve Coupling
37
Plant
• Split Muff Coupling: In split muff coupling, the sleeve or muff isn’t a single
different part instead it is split into 2. The muffs are semi-cylindrical in
shape which then fits over the shaft. Threaded holes are provided on the muffs so
that both the shafts can be joined with steel bolts or studs. The special feature of
this coupling is that it can be assembled and disassembled without changing the
position of shaft.
Applicat ion-
They are used for medium to heavy dut y load with moderate speed.
Figure 24: Split Muff Coupling
• Flange coupling: is also an easy to manufacture coupling and is similar to

sleeve coupling. Here, there are flanges on either side of the 2 sleeves. Both
the flanges consist of equal number of threaded holes for bolting purpose. The
flanges are then joined together with bolts and nuts. A key section is also
provided on the hub and shafts so that there is no slipping condition. A tapered
key is used here. This ensures that the hub doesn’t loosen up or move backward
and stays attached to the shafts.
Applicat ion-
Flange couplings are used for medium & heavy-dut y industrial
applicat ions.
38
Plant
Figure 25: Flange Coupling

23.2 Flexible Coupling: Flexible couplings are normally used in areas where the coaxially
between the connecting shafts is not always assured and in areas where there is a possibility of
occurrence of shocks in the transmission is applicable.
• Bush Pin Type: It is also like Flange Coupling. The only difference between them
is the usage of rubber bushings. Slightly thick rubber bushings are designed so
that the studs or bolts perfectly fit inside it and bushing fits perfectly inside the
holes provided.
The major advantage of using this coupling is that it can be used for slightly
misaligned shafts. The rubber bushings add a certain amount of flexibility to the
coupling which also helps to absorb shocks and vibrations.
39
Plant
Figure 26: Bush and Pin type
• Oldham’s Coupling: Oldham’s coupling is used to connect the two parallel shafts
when some eccentricity is present between two rotating shafts. In this the two
misaligned shafts have disc shape flanges with rectangular slot at the middle.
Both the flanges have slot cut which is at right angle to each other. In between
two shaft a circular disc assembled having tongue on both side at right angle to fit
between the slots of flanges. When shafts rotate then the tongue of the flanges
slides into the recess of the flanges of the shafts. The middle disc rotates about its
center but both the misaligned shafts rotate their own axis by means of sliding
tongue into the grooves which results the center of the middle disc traces a
circular orbit. The maximum sliding velocity of the both the tongue in the slots
will be the peripheral velocity for the middle disc at midpoint along the circular
orbit.
40
Plant
Figure 27: Oldham's Coupling
• Universal Coupling: This is also known as hook’s joint, universal joint or

coupling. It is called universal joint because it can able to joint two shafts having
intersecting axes. It is used to joint connect two non-parallel and intersecting
shafts which has some angular misalignment. The input and output shafts are
connected using hook’s joint. The input driving shaft rotates at a uniform angular
speed while the driven shaft rotates with varying angular speed i.e. both shafts
have different angular speed. Both the shafts rotate in fixed bearing and have a
fork at the end. Each fork has four ends and sides which are connected by center
piece. The center joint generally spherical in shape but can be cross and square
according to the requirement. At the center piece the arms of forks are join at right
angle. The fork connection between two shafts provides the motion to the
intersecting axes shafts. The main application of this coupling in automobiles
where it is used in power transmission from gear box to rear axle.
41
Plant
Figure 28: Universal Coupling
24. Bearing:
The word bearing is derived from the verb “to bear”. A bearing is a machine element that allows
one part to bear another. The main functions of bearings are
• To reduce friction between moving rotatory parts.

• To support rotating parts of a machine.
• To bear radial and thrust load
24.1 On Basis of friction:

It has two types.
24.1.1 Friction bearing:
As the name implies, in this bearings the bearing surface is in contact with moving surface or the
shaft which produces more friction. These bearing are made up of cast iron, bronze, brass, baibit
and white metal having hollow round shape. Lubricant is used for slow moving and heavy
weighted running on shaft. These bearings to support crack shaft, rocker arm of IC engine.
Friction bearing are also subdivided into following types
42
Plant
(A.) Solid bearings:
It is a simplest hole made in cast iron to support the shaft and form running fit. These are made
up of cast iron or bronze in the form of bush and press-fitted in fabricated or cast iron housings.
This is used for small and light shafts moving at low speed. A hole is provided on its face of
lubrication.
Figure 29: Solid Bearing
(B.)Split bearings:
Split bearings are same like solid bearings but have an arrangement of split. Split bearings are
made in halves and assembled in special plumber blocks. It has collar on its external surfaces and
also made in two parts as shown in figure.
43
Plant
Figure 30: Split Bearing

(C.)Self-aligning bush bearings:
It consist mainly two parts. The first one is cast iron block and other is bush. These bearing bush
are made up of brass or any other soft material in round shape. To protect it from moving, a
screw is fixed at one end and this screw is fixed half to the bush and half in block.
Figure 31: Self Aligning Bush Bearing

24.1.2 Anti-Friction bearing:
The main purpose of these bearings is to minimize the friction in bearing. Due to this reason, the
speed of an object increases and friction and temperature decreases. Such bearing have long life.
These bearing also sub-divided into following categories.
(A.) Ball bearings:
44
Plant
A ball bearing is a rolling element bearing that used ball to maintain the separation between the
bearing races. The width of these bearing is smaller than the bore diameter or ball. On the basis
of load and groove cut, ball bearings are classified in the following types.
(a.) Single row ball bearings:

These bearing have only one groove cut in outer and inner rings with the ball in identical line.
Figure 32: Single Row Deep Groove Ball Bearing

(b.) Double row ball bearing:
These bearing have two grooves cut in inner and outer ring lie in two rows of the bearing.
Figure 33: Double Row Ball Bearing

(c.) Self-aligning ball bearings:
These bearings can withstand with journal loads. These loads are generally inclined due to
shaft misalignment. These types of bearings have a spherical bore on the outer race.
45
Plant
Figure 34: Self Aligning Ball Bearing
(B.)Roller bearings:
Roller bearings are available with the grooved race in the outer and inner members. Roller
bearings are capable of carrying the journal (radial) loads. It can work with greater load than ball
bearings. To use this bearing, race is required to be locked. On the basis of uses, roller bearings
are classified in following types.
(a.) Tapered roller bearings:

These bearings are used to take thrust only one direction. For opposing thrust, the bearings must
be mounted in opposite pair. Tapered roller bearings are mainly used for high axial thrust loads.
Figure 35: Tapered Roller Bearing
46
Plant
(b.) Needle roller bearings:

These types of bearings have very small roller diameter. Rolling element is called needle roller.
Needle roller bearings are used where the outside diameter of bearing restricted due to limited
bearing space in the housing. The needles fitted in a circular cage which is push-fit in its
housing.
Figure 36: needle Roller Bearing
(c.) Cylindrical roller bearings:

These bearings are used in such places, where more load is to be bear. These are made of hollow
cylindrical roller.
Figure 37: Cylindrical Roller Bearing
47
Plant
Spherical roller bearings:

These bearings are used in such places, where chance of angular condition in shaft may be
possible. In these bearings, rollers are fitted in ball cage in such a way that in angular condition,
in inner and outer race, the energy transfer can be possible in full capacity.
Figure 38: Spherical Roller Bearing

24.2. On Basis of load: It has two types.
24.2.1. Radial or journal bearings:
In this type of bearing, the loading is at right angles to the bearing axis, such that bearing is
installed perpendicular to the axial line of the shaft.
Figure 39: Radial Thrust Bearing
48
Plant
24.2.2 Thrust bearings:

In these types of bearings, the loading is parallel to the bearings axis and collar is used to rotate
the shaft at one position.
Figure 40: Axial Thrust Bearing
25. Difficulty Faced during the Training:

❖ In the beginning we have faced issues of getting used to the environment but we found it
peaceful and cooperating.
❖ After 1 week no specific supervision provided that’s why sometime its create problems.
26. Feedback Regarding the Curriculum:
❖ Thanks to the faculty of mechanical Engineering department for providing us 1
month internship letter.
❖ During 1 month internship in thermal power Station, we learnt practically.
❖ Implementation of the subject theories especially relevant to mechanical subjects.
❖ It was very good mixture of theoretical and practical training."
❖ "The training course helped me in all areas that I was previously studied in my subjects.
❖ The training was very informative and practically implemented.
❖ "The syllabus was excellently delivered all aspects were clearly explained especially
Generation
cycles.
❖ "We have picked up a lot of factual information regarding the subjects.
❖ "The trainer was very experienced and was able to answer all of our queries."
❖ The instructor was very knowledgeable and the training had a good mixture of learning
activities."
Thank you
49

Thermal Power Plant

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Thermal Power Plant

Uploaded by

Copyright:

Available Formats

NORTHERN POWER GENERATION COMPANY

Engr. Muhammad Shahid

COMSATS University Islamabad Sahiwal

1. Plant Layout ………………………………………………………………08

2. Fuel Oil Tanks…………………………………………………………….09

2.1 Furnace Oil Flow Cycle ………………………………………………09

3. Mission Statement ………………………………………………………..10

3.1 Background …………………………………………………………………..10

5.1 Water Tube Boiler ……………………………………………………………..13

5.13 Feed Water Pump……………………………………………………………….17

7. Chemical Treatment Plant…………………………………………………….20

7.1 External Treatment………………………………………………………………..20

8.1 Gate Valve……………………………………………………………………….22

10. Rankine Cycle………………………………………………………………..24

11. Components of Steam Turbine………………………………………………25

11.5 Governor System………………………………………………………………..25

12. Stages of Steam Turbine……………………………………………………26

13. Steam Turbine Generator………………………………………………..26

14. How It Works? .............................................................................................26

15. Generator Cooling System……………………………………………….27

16. Jacking Oil Pump………………………………………………………...27

17. Centrifugal Pump…………………………………………………………28

19. Condensate Pump…………………………………………………………29

23. Types of Coupling……………………………………………………….30

23.1 Rigid Coupling………….………………………………………31

24.1 On Basis of Friction……………………………………………..34

2. Fuel Oil Tanks:

2.1. Furnace Oil Flow Cycle:

Figure 1: Furnace Oil Flow Cycle

• • Generation, transmission and distribution.

Figure 2: Muzaffargarh Thermal Power Station

There are two phases working at thermal power station Muzaffargarh.

The phase-1 can produce 15120000 units/24 hrs.

4.3 Some Key Facts:

5.1 Water Tube Boiler

Figure 3: Water Tube Boiler

5.2 Major Components of Water Tube Boiler:

5.3 Working of Water Tube Boiler:

5.4 Balanced Draft Boiler:

Figure 4: Balanced Draft System

5.5 Induced Draft Fan:

5.6 Forced Draft Fan:

5.7 Gas Recirculation Fan:

Figure 5: Super Heater

5.9 Soot Blower:

Figure 6: Soot Blower

5.10 Combustion Cycle:

Figure 7: Combustion CycEle in Boiler

5.12 Boiler Feed Water Tank:

5.13 Feed Water Pump:

Week 2 –Cooling Tower and Chemical Plant

Figure 9: Cooling Tower

6.3 Cross flow Cooling:

Figure 10: Cross Flow Cooling

6.4 Circulating Water Pump:

7. Chemical Water Treatment:

7.1 External Treatment:

7.2 Internal Treatment:

7.3 Water Purification System:

• Vibrations in the turbines and damage its blades.

7.4 Mechanical Filters:

7.5 Cation Filter 1:

7.7 Anion Filter:

7.8 Cation Filter 2: