INDEX

Overview of GSECL WTPS

Wanakbori Thermal Power Station is a coal-fired power station in Gujarat, India.
It is located on the bank of mahi river in Kheda district. There are eight units at this
location, seven of each 210 MW and one of 800 MW capacity.

i.e., They have the capacity to produce 210 MW and 800 MW per hour respectively.

GSECL had recently entrusted BHEL with an order for setting up an 800MW
supercritical coal-based project at Wanakbori in Gujarat on EPC basis. BHEL has
completed the construction activities and the 800MW was declared as
commercially operational on 12.10.2019 at 14:00 Hrs.

Stage Unit Installed Date of Status

Number Capacity Commissioning

Stage 1 1 210 March 1982 Running

Stage 1 2 210 January, 1983 Running

Stage 1 3 210 March, 1984 Running

Stage 2 4 210 March, 1986 Running

Stage 2 5 210 September 1986 Running

Stage 2 6 210 November 1987 Running

Stage 3 7 210 December 1998 Running

Stage 4 8 800 October 2019 Running

This project constructed in two phases i.e., stage 1 and stage 2 each of 3 X 210 MW
unit.
For stage 1 the foundation stone laid by late prime minister shri Morarjibhai Desai
in 1978. Unit 1, 2, and 3 are commissioned on 23/03/1982. 15/01/1983 and
15/03/1984 respectively. These units are supplied, erected and commissioned by
M/S BHEL and provided boiler of American combustion design and Russian
designed LMW make turbines the project cost for this stage was 259.09 corers.

For stage 2 the foundation stone laid by late prime minister smt Indira Gandhi in
1982. Unit 4, 5. And 6 are commissioned on 9/03/1986, 23/09/1986 and
18/11/1987 respectively. These units are also supplied, erected and
commissioned by M/S BHEL and provide high pressure boiler of American
combustion design and west Germany KWU designed turbines. These turbines
are equipped with advance electronic AUTOMATIC TURBINE RUNUP SYSTEM
(ATRS). The Project cost for this stage was 318.8 cores. Including the unit no. 7
there are total seven nos. of turbo generator set each having capacity of 210 MW,
3000 RPM. 15.75 KV. 247 MVA.

Being coal based thermal power station it is provided with coal plant comprise of
being coal based thermal power station. Each of having capacity to unload 10
wagons/hour. Primary crusher house secondary crusher house and connecting
network of coal belt having 2000 Mt/Hour coal of flow capacity with stacker -
reclaimed having capacity. The required coal is getting through coal India
authority from coal mines of Bihar, M.P. Orissa, West Bengal. the coal is
transported from coal mines to Sevaliya via Ratlam-Godhara railway track.
Generally, 300 wagons of coal being received here to daily to meet the
requirement is generally 19000 tons per day.

The main water sources for water make up to power house are Mahi River main
canal and tube wells. The designed water requirement /unit is 13 cusec. The
stage wise clarifier and D.M. plant is provided to remove the impurities from raw
water to make the water suitable for boiler. Total 1830 employees are working
including 425 engineers. Compare the national average of 2.6 employee/MW the
staff working at the power station is 1.45 employees/MW which is quit less.

A Thermal Power Plant converts the heat energy of coal into electrical energy. Coal
is burnt in a boiler which converts water into steam. The expansion of steam in
turbine produces mechanical power which drives the alternator coupled to the
turbine.
 Area visited

• BMD-lll (Boiler Maintenance Department):-

1. Control Room (5,6).

2. Boiler Area.
3.ID & FD Fan .
4. Coal Yard.
5. Cooling Tower.
6. Ash collection plant.

• Mechanical and Instrument Department

1. Steam Turbine.
2. Control room.
3. Boiler Area.
4. Auxiliary boiler.
5. Compressor.
6. PT plant.
7. DM plant.
8. C.P.U (Condensate polishing unit).
9. Jackwell.
Thermal Power Plants contribute maximum to the generation of Power for any
country. Thermal Power Plants constitute 75.43% of the total installed captive
and non-captive power generation in India.

BLOCK DIAGRAM OF POWER PLANT

GENREAL LAYOUT OF THERML POWER STATION
 Coal
Cycle

Trains

Wagon tippler

Coal Yard

Primary
Crusher(75 mm)

Secondary
Crusher(25 mm)

Bunker

Gravimetric
Feeder

Coal Mill

Boiler
 COAL CYCLE COPONENTS

1. Transportation (Train):
Wanakbori power station is coal base power station. It uses coal as its fuel. Bituminous
coal is used in the Wanakbori power station. Wanakbori received coal mainly from coal
mines situated at Orissa, Madhya Pradesh, West Bengal, Andra Pradesh,
Chhattisgarh Mines (south eastern collieries Ltd), WCL (Western Collieries Ltd) &
Korea reva mines.

2. Wagon Tippler:
To unload received coal rack, Wanakbori thermal power station has wagon tippler house.
There is total 5 number of tipplers which unloads record 710 numbers of wagon in single
day.

Total 5 wagon tipplers installed. 1,2,4 is made by elechon & tippler 5 is hydraulic.

5 to 7 racks received per day.

Each railway train carrying 58 wagons is called one rack. each wagon loads 60 ton of coal
which means each rack loads 3600 MT Approximately Total 18000 MT - 21000 MT of coal
is consumed daily to generate power of 1470 MW.

Grade Calorific Value (Kcal/kg)

A 6200 & above

B 5601 to 6200

C 4941 to 5600

D 4201 to 4940

E 3361 to 4200

F 2401 to 3600

G 1300 to 2400
3. Coal Yard:
The coal yard is a storage area where all the coal is stored in number of tonnes
which is coming from via transportation (Train).

4. Stacker Reclaimer:
It has 2 modes of operation:
1. Stacking:
The material on the forward moving yard conveyor is raised by the tripper and
discharged through a discharge guide chute onto an intermediate inclined
conveyor which, lift the material and ultimately discharges on to the boom
conveyor by a chute. The boom conveyor carries the material up to its end and
allow it to fall from a stockpile. The stacking operation starts at one end of the
stockpile with the boom kept low. The travel motion operates simultaneously
and at the other end of the stockpile, the motor reverse. After a number of such
cycle the boom is luffed up and the cycle repeated.
 2. Reclaiming:
The machine reclaims the material from the stockpile in layers by rotating
bucket wheel swing across the pile. The material picked up by the bucket is
retained and guided by the ring chute as the bucket moves up. When the bucket
is about 45 degrees above horizontal, the material starts discharging it to the
bucket wheel chute, which guides it to the boom conveyor. On reaching the end
of the boom conveyor, the material passes through the central chute and portal
chute on to the yard conveyor belt, supported on the impact table.

5. Conveyor Belt:
It is moving over a pair of end drums roller. At some distance a supporting roller is
provided at the center. The belt is made up of rubber & nylon. It is suitable for the
transfer of coal over long distances. The inclination at which coal can be successfully
elevated by belt conveyor is about 20.

Total length of conveyor belt is around 16 km. width of conveyor belt is 1500mm,
1400mm &1200mm. belt speed is 3.3-3.6 m/sec.
6. Primary Crusher:
In primary crusher size of coal is max about 125 mm capacity which is
crushed and becomes 75mm. Primary crusher is 1100 MT/hour. 1A,
1B,1C, 1D is installed.
7. Secondary Crusher:
In secondary crusher size of coal is crushed from 75mm to 25mm.
Secondary crusher is nearly 1100MT/hour. 2A, 2B, 2C, 2D is installed.
“Magnetic separators are provided in plant to remove iron or uneven
impurities in coal. Two magnetic separators are provided.”

8. Bunker:
Now this coal goes into the bunkers with the help of conveyor belt. Total 6
bunkers areused per unit. But only 5 is in running condition and 1 is taken
as spare. Hoppers are used to weigh the quantity of coal.
6. Gravimetric Feeder:
The gravimetric feeder consists of the conveyor belt in it, so when coal comes from the
bunker first it falls on this conveyor belt i.e., on the left side of this belt. After that the
coal is allow to move on this belt as this belt moves towards right side hand
respectively. As the coal reaches at the right end of the conveyor belt it falls down in the
passage when goes to the mill.
7. Boiler:
Fuel such as pulverized coal is air-blown into the furnace through burners located at
the four corners, or along one wall, or two opposite walls, and it is ignited to rapidly
burn, forming a large fireball at the centre. The thermal radiation of the fireball heats
the water that circulates through the boiler tubes near the boiler perimeter. The water
circulation rate in the boiler is three to four times the throughput. As the water in the
boiler circulates it absorbs heat and changes into steam. It is separated from the water
inside a drum at the top of the furnace. The saturated steam is introduced into
superheat pendant tubes that hang in the hottest part of the combustion gases as they
exit the furnace.

> Stage I & II: Tangentially Fired, Balance Draft, Natural Circulation, Radiant Reheat

> Stage III: Vertically Suspended Water Tubes, Radiant Reheat Cycle, Natural
Circulation

> Height of Boiler: 52 m

> Capacity: 700 Tones / hr.

> Feed Water Temp.: 250°C

> Steam Temperature: 535°C

> Force Draft Fan: 2 Nos

> Induced Draft Fan: 2 Nos

> Primary Air Fan: 2 Nos

> Coal mill: 6 Nos per unit

-- Types of oils used in boiler:

Here to light-up the boiler in the beginning we use the 2 types of oils and they are 1.)
Furnace oil (FO) and 2.) Light diesel oil (LDO). At first, we use LDO to light-up which is
sprayed from light guns into boiler and once it seems that ignition takes place then we
supplied FO from the light run into the boiler for ignition.

-- Development of circular process (Fireball):

The circular furnace concept is somewhat related to the well-known fireball concept
using a corner-fired configuration for power station boilers. When considering the fact
that the fireball is of an approximately circular shape (Fig. 2), while the traditional
boiler is square, with dead volumes near the corners, the question comes to mind
whether there are any possibilities of reducing the steel requirements of the boiler by
changing its shape.
The reduction in the circumference indicates that a significant reduction in steel
requirements may be possible by approaching a circular furnace concept. Again,
considering the fireball, it is evident that there is also a hole in the centre of the fireball.
Whilst keeping the surface area of the waterwalls constant, some of the surface area at
the top of the furnace waterwalls could be moved to line the hole in the fireball centre.
Moving this surface area reduces the height of the boiler while keeping the total heat
transfer area constant, which leads to a further significant reduction in steel
requirements, mostly structural steel in this case. Fig. 3 illustrates the position of the
waterwall heat transfer surface relative to the fireball in a circular furnace boiler. The
actual furnace is octagonal and not perfectly circular for practical construction reasons.

8. Super Heater:
It is integral part of the boiler and is placed in the path of hot flue gases from the
furnace. The heat recovered from the flue gases is used in superheating the steam
before entering into the turbine. Its main purpose is to increase temperature of
saturated steam without raising its pressure. In WTPS the regenerative super-heater is
used.

9. Re-Heater:
They are the same as the super-heaters but as their exit temperature is a little bite less
than super heater and their pressure is 20%-25% less than the super-heater. Re-heater
tube are commonly (44.5) x5 mm in OD.

10. Boiler Furnace and Drum:

The water enters the boiler through a section in the convection pass called the
economizer. From the economizer it passes to the steam drum and from there it goes
through downcomers to inlet headers at the bottom of the water walls. From these
headers the water rises through the water walls of the furnace where some of it is
turned into steam and the mixture of water and steam then re-enters the steam drum.
This process may be driven purely by natural circulation (because the water is the
downcomers is denser than the water/steam mixture in the water walls) or assisted
by pumps.

In the drum, the water is returned to the downcomers and the steam is passed through
a series of steam separators and dryers that remove water droplets from the steam. The
dry steam then flows into the superheater coils. The steam drum (as well as the
superheater coils and headers) have air vents and drains needed for initial start-up.
 WaterandSteamCycle(RankineCycle).

Condenser
LPT CE Pump

IPT Hotwell

Reheater LP heaters

HPT Deaerator

Superheater Boilerfeed
pump

BoilerDrum FCV 1,2,7

Economizer
1. Condenser.
The Steam which is used to rotate the LPT (low pressure turbine) is then sent to the
condenser where the steam is converted to the water where temperature of the water is
about 40°C.
Now the question is how the steam is cooled in the condenser?
The water from cooling tower is sprayed onto steam in condenser to cool down the steam.

2. CE PUMP (condensate extraction pump).

Condensate extraction pumps extract the condensate water from the condenser and pump
it through the condensate polishing system and the LP heater to the deaerator feed water
tank.

3. Hotwell: A tank or reservoir in which hot water is collected before being recirculated,
especially condensed steam about to be return to a boiler.
4. LP heaters.
They provide a lost additional point for retrieving latent heat for heating condensate
feedwater and therefore give additional economy to the system.
As such they do not heat the condenser. Instead, they cool the steam and condense before
it reaches the condenser tubes because it is positioned just above the condenser in the same
shell or containment vessel as the condenser, hence the terminology that it is in the
condenser.
5. Deaerator.
Deaerators are mechanical devices that remove dissolved gases from boiler feedwater.
Deaeration protects the steam system from the effects of corrosive gases. It accomplishes
this by reducing the concentration of dissolved oxygen and carbon dioxide to a level where
corrosion is minimized.

6. Boiler feed pump.

Boiler feedwater pumps transport water into boilers using high pressure. Thus, a boiler feed
pump is built to handle extremely high-water pressure to deliver the feedwater into the
boiler system. Generally, a boiler feed pump can handle the pressure of up to 100 bar.
There are two types of pumps that are most often used for boiler feed water applications:
stamped stainless steel vertical multistage inline pumps and multistage horizontal ring
section pumps.

7. FCV (flow control valve).

A flow control valve regulates the flow or pressure of a fluid. Control valves normally
respond to signals generated by independent devices such as flow meters or temperature
gauges.

8. Economizer.
An economizer is a mechanical device used to reduce energy consumption. Economizers
recycle energy produced within a system or leverage environmental temperature
differences to achieve efficiency improvements.
The economizer also prevents flooding of the boiler with liquid water that is too cold to be
boiled given the flow rates and design of the boiler. A common application of economizers
in steam power plants is to capture the waste heat from boiler stack gases (flue gas) and
transfer it to the boiler feedwater.
 9. Boiler Drum.
It is a reservoir of water/steam at the top end of the water tubes. The drum stores the
steam generated in the water tubes and acts as a phase-separator for the steam/water
mixture.

10. Superheaters.
A superheater is a device used to convert saturated steam or wet steam into superheated
steam or dry steam. There are three types of superheaters: radiant, convection, and
separately fired.

11. HPT (high pressure turbine).

HP Turbine (high-pressure turbine) is usually a double-flow turbine element with an
impulse control stage followed by reaction blading at each end of the element. There are
about 10 stages with shrouded blades in the HP turbine. It produces about 30-40% of the
gross power output of the power plant unit.
12. Reheater.
The steam from the HPT loses some temperature so the reheaters are used to reheat the
steam for further usage.

13. IPT (Intermediate pressure turbine).

The steam from high pressure turbine is sent to the reheater to increase the temperature
of the steam and thus increasing the pressure of the steam. This steam is then used to
rotate the IPT.

14. LPT (Low pressure turbine).

LPT is a turbine designed specifically for low values of pressure ratio (1.05-1.30), allowing
extraction of residual exhaust energy downstream. of the turbocharger, whilst minimizing
negative engine performance impact due to increased exhaust back pressure.
 Air and flue gas cycle
Atmosphere

Chimney ID fan

ESP

Hot air
Air preheater FD fan

Feed water
Boiler feed Pump
Economizer

Wet Steam Dry Steam

Boiler Superheater

Flue gas

- Flue Gas

- Wet Steam

- Dry Steam
- Hot Air
1. PA Fan.
PA fan also known as Primary air fan. Primary air fans provide high-pressure air
to the boiler system, which enters it through the APH. This air is used to dry coal
and convey it to the furnace from the mill. It also feeds oxygen for primary
combustion into the boiler. Both cold and hot primary air may be provided by
the PA fan.

2. Air preheater.
Air preheater is used to heat the air provided by the PA fan and FD fan from the
atmosphere which helps in the combustion of the coal and thus increasing the
efficiency of the system.
3. Coal mill.
A coal mill is also called a coal pulverizer or coal grinder. It is a mechanical device
used to grind raw coal into pulverized coal powders.
 Pulverization is being used not only for reducing particle size but also as an
operation for developing new materials.
*Coal Fineness -Coal fineness is a relative measurement of particle size
distribution typically applied to the product leaving a pulverizer.

4. Bunker.
Many plants like coal fired power plants, employ coal bunkers to store coal and
coal mills to crush the raw material into fine particles before being injected into
the boiler.
5. FD Fan.

Forced Draft Fans (FD) supply the air necessary for fuel combustion by push in
gear through the combustion air supply system and into furnace. These fans are
located at the inlet of boiler to push high pressure fresh air into combustion
chamber, where it mixes with the fuel to produce positive pressure.
 6.

Economizer.
Economizer in thermal power plant is used to store the water which is then feed
to the boiler. Now the main purpose of the economizer is to send hot water to
the boiler to increase its efficiency. This water is heated by flue gases obtained
from the boiler.
7.

ESP.

ESP or electrostatic precipitator is used to filter out the flue gases by extracting
the carbon particles from the gases using DC voltage. The device filters out
particles such as fumes, fly ash and suspended dirt from the gas stream before

releasing them out of the chimney. The key principle of the devices is to use a
very high voltage negative charged electrostatic force.
8.

ID fan.
An ID fan or induced draft fan is used to extract flue gases from the system into
the atmosphere by creating a vacuum of negative air pressure.
9.

Chimney (Stack).
A chimney is the tallest structure in the power plant for venting hot flue gases
or smoke from a boiler, stove, furnace, or fireplace to the external atmosphere.
These power plant chimneys are sometimes known as stacks.
 Water Treatment Cycle.

River

Jack well Pump

PT plant

DM plant

Economizer

1. Jack Well.
It is a type of intake tower within which the water level is practically similar to
the level of the sources of supply. It is known as Jackwell and is most commonly
used. Jackwell structures are used for accumulating water from the surface
sources like a river, lake, and reservoir.
2. PT plant (Pretreatment plant).

Pre-treatment is the preliminary removal of wastewater or sludge constituents,

such as oil, grease, and various solids (e.g., sand, fibres and trash).
 Built before a conveyance or treatment technology, pre-treatment units can retard
the accumulation of solids and minimize subsequent blockages.

3. DM Plant (Demineralization Plant).

Demineralization is the process of removing mineral salts from Water by using the
ion exchange process. Demineralized Water is Water completely free ( or almost )
of dissolved minerals as a result of one of the following processes : Distillation.
Deionization.

Demineralization plant employs a chemical method to separate out the dissolved salt in raw
water.
The function of demineralization plant is to remove dissolved salt by ion exchange method
(chemical method) and there by producing pure feed water for boiler.
In D M plant there are three types of resin used for boiler feed water treatment process:
1. Cation exchange resin
2. Anion exchange resin
3. Mixed Bed resin

Resins are chemical substances (usually polymers of high molecular weight) used to react
with salts and eliminates them by chemical process.

As the name suggests, the cation exchange resin, exchanges the cation and anion exchange
resin, exchanges anions with the salts dissolved in hard-water.

Cation Exchange Resin

NaCl + RSO3H =
Thus H2SO4, H2CO3 are also produced.
Anion Exchange Resin.
This way we have eliminated Cl– and thus acidity of the water. Similar
reaction for H2SO4 also.

Mixed Bed Resins

These mixed bed resins are used in Demineralization plant of boiler feed water treatment, to
remove the ions (especially Na+ and SO32-) which may further present in the water after
foregoing process of purification.
 Measurement Instruments in Thermal Power plant.

For a plant, measurement system needs to be:

• Very accurate
• Reliable
• Delays should be as small as possible
• Should be switched on manually when an overall control system fails

Quantities To be measured in thermal Power Plant are:

• Pressure
• Temperature
• Flow
• Level
• Expansion
• Vibration
• Analysis- water, steam, flue gases

Now the Question is why do we use Instruments in Power

Plant?
We use Measurement instruments for
• Efficient operation of the plant
• Economic operation of the plant
• Safe Operation of the plant
• Pollution control
This entire task is often taken up by control and instrumentation or simply
instrumentation system which has following functions:
• Measurement
• Control
• Operation
• Monitoring
• Protection

Measurement Points and Variable

1.Pressure
➢ Measuring points in Power plant
• Boiler

• Turbine

• Turbine throttle

• Furnace

➢ Types of sensors/instruments for pressure measurement

• Bourdon tube
• Diaphragm
• Bellows
• Bell gauges
2.Temperature

Measuring points in power plant

• Steam at superheater inlet and outlet

• Feed water at economizer inlet
• Water at condenser inlet
• Air preheater
• Flue gases
• Bearing of turbine and generator
• Feed pump, condensate pump

Types of sensors/instruments for temperature measurement

• Thermocouple
• RTD

3. Flow
Measuring points in power plant
• High pressure steam
• Feed water inlet
• Condensate

Types of sensors/instruments for flow measurement

• Orifice
• Venturi tube
• flow nozzle
4. level

Measuring points in power plant

• Boiler drum
• Condensate tank
• Water line

Types of sensors/instruments for level measurement

• Differential pressure methods

5. Expansion

Measuring points in power plant

• Turbine shaft
• Turbine casing

Types of sensors/instruments for expansion measurement

• Relative displacement

6. Vibration

Measuring points in power plant

• Turbine and generator shaft and bearing shells

Types of sensors/instruments for vibration measurement

• Mass spring with potentiometric capacitive
• Eddy current
• Piezo electric
 • Optical types

7. Analysis

(i) Water
Measuring points in power plant
• Feed water at economizer
• Boiler inlet
• Condenser
• Condensate pump discharge

Types of sensors/instruments for water analysis

• Conductive cell with meter

(ii) Steam
Measuring points in power plant
• Saturated steam
• Main line steam
• Super heater inlet

Types of sensors/instruments for steam analysis

• Conductive cell with meter
• Na analyzer

(iii) Flue gases

Measuring points in power plant

• O2 - Economizer to air heater
• CO2 - Air heater inlet and outlet
• CO - Stack
• SO2 - Stack
• Nitrogen oxide - stack
• Dust conc.-stack

Types of sensors/instruments for flue gas analysis

• Zirconia cell
• CO2 analyzer
• CO analyzer
• SO2 analyzer
• N – oxide Analyzer
• Optical method
Finally, we would like to thank all the Engineers, technicians,
workers at W.T.P.S for helping and guiding us throughout our
internship training program and educating us in a very practical
aspect. We really appreciate the effort they have contributed to
our training program. We sincerely appreciate their flexibility and
willingness to help. And finally, we are very grateful to complete
our summer internship program at W.T.P.S.

Special thanks
Bhavesh sir
Chirag sir
Hardik sir
Miraj Patel sir
Jay Thakkar sir
Bhargav sir
Nikhil sir
Arif sir
V.D Upadhyay sir
Rahul Solanki sir
Pranav Bhatt sir
 GUJARAT TECHNOLOGICAL UNIVERSITY
CERTIFICATE FOR COMPLETION OF ALL ACTIVITIES AT ONLINE PROJECT PORTAL
B.E. SEMESTER VII, ACADEMIC YEAR 2021-2022
Date of certificate generation : 21 July 2022 (17:20:54)

This is to certify that, Parmar Akshatsinh Vanrajsinh ( Enrolment Number -

190600119030 ) working on project entitled with Summer internship at WTPS
from Mechanical Engineering department of GOVERNMENT
ENGINEERING COLLEGE, GODHARA had submitted following details at
online project portal.

Internship Project Report Completed

Name of Student : Parmar Akshatsinh Name of Guide : Mr.BHATT VIPUL

Vanrajsinh RAMESHCHANDRA

Signature of Student : _____________ *Signature of Guide : ________________

Disclaimer :
This is a computer generated copy and does not indicate that your data has been evaluated. This is the receipt that GTU
has received a copy of the data that you have uploaded and submitted as your project work.

*Guide has to sign the certificate, Only if all above activities has been Completed.