Summer Internship Report

(30/07/2023 – 28/07/2023)

Thermal Power Station, Muzaffargarh

SUBMITTED BY:
Abd ur Rahma (2021-ME-509)
Junaid Rasool (2021-ME-510)
Muhammad Awais Iqbal (2021-ME-517)
Basit Raza (2021-ME-532)
Ghazanfar Hussain (2021-ME-536)
Umar Zafar (2021-ME-538)
SUBMITTED TO:
ENGR. SAJAD AHMAD

UNIVERSITY OF ENGINEERING AND TECHNOLOGY, LAHORE

(NAROWAL CAMPUS)

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Table of Contents
Table of Figures........................................................................................................................................... 4
PREFACE: .................................................................................................................................................. 5
T.P.S MuzaffarGarh ................................................................................................................................... 6
Introduction: ............................................................................................................................................... 6
1. Phase #01 (Unit #01, 02 & 03): ........................................................................................................... 8
1.1. Main Building: .............................................................................................................................. 8
1.2. Combined Auxiliary Building:...................................................................................................... 8
1.3. Fuel & Oil Facilities: .................................................................................................................... 8
1.4. Hydraulic Structures: .................................................................................................................... 8
1.5. Startup Boiler: ............................................................................................................................... 9
1.6. Electrical Part: ............................................................................................................................... 9
2. Phase#02 (Units #05 & 06): .............................................................................................................. 10
2.1. Overview:.................................................................................................................................... 10
3. Steam Turbine:.................................................................................................................................. 11
3.1. HP (High Pressure) Turbine:....................................................................................................... 11
3.2. IP (Intermediate Pressure) Turbine: ............................................................................................ 11
3.3. LP (Low Pressure) Turbine: ........................................................................................................ 11
3.4. Turbine Protection: ..................................................................................................................... 12
4. The Generator: .................................................................................................................................. 13
4.1. Working Principle: ...................................................................................................................... 13
4.2. Turbine Generator Water Hydrogen Cooled:.............................................................................. 14
4.3. Cooling System of Turbo Generator: .......................................................................................... 14
4.3.1. Stator Cooling: ........................................................................................................................ 15
4.3.2. Rotor Cooling: ........................................................................................................................ 15
4.4. Water Parameters in Gas Cooler: ................................................................................................ 16
4.5. Protections of Generator: ............................................................................................................ 16
5. Boiler: ................................................................................................................................................. 17
5.1. Water Tube Boilers: .................................................................................................................... 17
5.2. Boiler Parameter: ........................................................................................................................ 18
5.3. Main Parts of Boiler: ................................................................................................................... 18
5.4. Boiler Drum: ............................................................................................................................... 19
5.5. Air Pre-Heater: ............................................................................................................................ 19
5.6. Economizer: ................................................................................................................................ 19
5.7. Furnace:....................................................................................................................................... 19
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 5.8. Burner: ........................................................................................................................................ 19
5.9. Accessories of Boiler: ................................................................................................................. 19
5.10. Force Draft Fan (FDF): ........................................................................................................... 20
5.11. Induced Draft Fan (IDF): ........................................................................................................ 20
5.12. Gas recirculation fan (GRCF): ................................................................................................ 21
5.13. RAH: ....................................................................................................................................... 21
5.14. Calorifier: ................................................................................................................................ 21
5.15. Boiler Protection: .................................................................................................................... 22
6. Furnace Safeguard Supervisory System (FSSS): ........................................................................... 23
6.1. Decanting Area: .......................................................................................................................... 23
6.2. Fuel Oil Tanks: ........................................................................................................................... 23
6.3. First Lift Pump: ........................................................................................................................... 23
6.4. Main Heaters: .............................................................................................................................. 24
6.5. Second lift Pump: ........................................................................................................................ 24
7. Cooling Towers: ................................................................................................................................ 25
7.1. Circulating water pump motor: ................................................................................................... 25
7.2. CW Pump:................................................................................................................................... 25
8. Cycles: ................................................................................................................................................ 26
8.1. Steam Cycle: ............................................................................................................................... 26
8.2. Condenser Cycle: ........................................................................................................................ 27
8.3. Feed water Cycle: ....................................................................................................................... 26
8.4. Fresh Air Cycle: .......................................................................................................................... 28
8.5. Flue Gases Cycle: ....................................................................................................................... 28
Conclusion: ................................................................................................................................................ 29
Acknowledgement:.................................................................................................................................... 30

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Table of Figures
Figure 1: T.P.S MuzaffarGarh ...................................................................................................................... 6
Figure 2: Main Building................................................................................................................................ 8
Figure 3: Turbine Hall ................................................................................................................................ 11
Figure 4: Accessories and Parts of Boiler Diagram .................................................................................... 21
Figure 5: Cooling Towers ........................................................................................................................... 25

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PREFACE:
To be able to cope with the changing environment it is necessary to have some practical
experience. As a student of mechanical engineering, I must pass through a series of various
techniques. During this practical course I am provided with an opportunity to learn how knowledge
can be implemented in a practical field.
I selected to do my internship in Thermal Power Station Muzaffargarh. I worked there for
four weeks & it gave me a greater practical knowledge about the operations of a Thermal Power
Station Muzaffargarh. In the following pages I have narrated my experience, observations & all
the working activities which I observed during our four-week internship in Thermal Power Station
Muzaffargarh.

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T.P.S MuzaffarGarh
Thermal Power Station Muzaffargarh is a 1,370-megawatt (MW) fuel oil- and gas-fired
power station in Punjab province, Pakistan.
The power station consists of the following units: three units of 210 MW each, two of 200
MW each, and one of 320 MW. They were completed between 1993 and 1997, and are fuel led by
natural gas and fuel oil. The power station is owned and operated by state-owned Northern Power
Generation Company Limited (GENCO-III).
As per 'State of Industry 2022' Report, Units 2,5 and 6 are in stand-by mode, while Unit 4
is damaged. Utilization of Unit 1 and Unit 3 is very low.

• Owner: Northern Power Generation Company Limited (GENCO-III)

• Parent company: Pakistan Electric Power Company (PEPCO)
• Location: Muzaffargarh, Muzaffargarh district, Punjab province, Pakistan
• Coordinates: 30.1055586, 71.1638546 (to be exact)
• Status: Operating
• Gross generating capacity (operating): 1350 MW

Thermal Power Station Muzaffargarh uses dual fuel combustion provision (gas or furnace
oil) and has been made for all machines. Furnace oil is transported through Railway Wagons and
Tank lorries.

Figure 1: T.P.S MuzaffarGarh

Introduction:
Thermal power plants are electricity generation facilities that produce electricity by
converting heat energy into electrical energy.

Chemical energy ▬ Heat energy ▬ Mechanical energy ▬ Electrical energy

This process involves burning fossil fuels such as coal, natural gas, or oil to produce high-
pressure steam that drives a turbine connected to an electricity generator. The generator, in turn,
converts mechanical energy into electrical energy, which is then transmitted through the power

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grid to homes, businesses, and industries. Thermal power plants have been vital in addressing
Pakistan's energy needs and bridging the gap between supply and demand. They provide a reliable
and consistent source of electricity, helping to support economic growth, industrialization, and
improved living standards for the population. Additionally, thermal power plants contribute to the
stability of the national power grid, ensuring a constant supply of electricity across the country.
While thermal power plants are a significant asset to Pakistan's energy sector, they also
pose challenges and environmental concerns. Burning fossil fuels releases greenhouse gases and
other pollutants, contributing to air pollution and climate change. To address these issues, the
government and energy stakeholders are increasingly exploring cleaner and more sustainable
alternatives, such as renewable energy sources and advanced technologies for emissions reduction.
Thermal power plants play a crucial role in Pakistan's energy sector, providing a substantial portion
of the country's electricity supply. As the nation seeks to balance its energy needs with
environmental sustainability, there is an ongoing effort to diversify the energy mix and explore
greener options. Through continued investments in renewable energy and technological
advancements, Pakistan aims to achieve a more balanced, reliable, and environmentally friendly
energy landscape for its citizens.
Installed capacity:
1. Phase-I (Russian Made)
• Unit 1-1: Gas- and fuel oil-fired steam turbine, 210 MW
• Unit 1-2: Gas- and fuel oil-fired steam turbine, 210 MW
• Unit 1-3: Gas- and fuel oil-fired steam turbine, 210 MW
2. Unit-IV (China Made)
• Unit 4: Gas- and fuel oil-fired steam turbine, 320 MW
3. Phase-II (China Made)
• Unit 2-1: Gas- and fuel oil-fired steam turbine, 200 MW
• Unit 2-2: Gas- and fuel oil-fired steam turbine, 200 MW

Unit COD Fuel Installed Capacity

TPS Muzaffargarh (MW)
Unit 1 1993 Gas/FO 210
Unit 2 1994 Gas/FO 210
Unit 3 1995 Gas/FO 210
Unit 4 1997 Gas/FO 320
Unit 5 1995 Gas/FO 200
Unit 6 1995 Gas/FO 200
Sub- Total 1350

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1. Phase #01 (Unit #01, 02 & 03):
This phase consists of three steam units each capable of generating 210MW electricity.
The supplier started delivery of equipment to the site in 1989 and after pre-assembly of equipment
at site, erection started in 1990. Unit#1 was commissioned in 1993 and unit#2 in 1994.
1.1. Main Building:
It contains the turbine hall having a span of 45m and deaerator bay, 12m wide. The steam
turbines which drive generators are of three stage condensing type arranged transversely to the
axis of turbine hall. The operational platform is at elevation 12.6m and there is a maintenance bay
on the ground floor near unit#1. The power plant is designed with block principle: boiler-turbine-
generator-unit transformer. The flue gas exhaust section of two units relates to a 200m (about
656.17 ft) high stack, outer section of which is a 195m (about 639.76 ft) high concrete shell.

Figure 2: Main Building

1.2. Combined Auxiliary Building:
The building relates to the main building, and it houses a water treatment plant to produce
100t/h dematerialized water for the replenishment of station losses. The hydrogen plant provides
hydrogen for cooling of generator's r rotor, maintenance shops, laboratories, and central control
room.
1.3. Fuel & Oil Facilities:
Fuel oil facilities are constructed for decanting, oil storage, preparation and supply of fuel
to boiler nozzles. It also includes HSD storage as well as oil facilities for reception, storage,
purification and centralized delivery of turbine oil and insulating oil to power plant.
1.4. Hydraulic Structures:
The cooling water used in condensers is re-circulated in closed cycle with indicated draft
cooling towers, the water is being cooled for each unit in two cooling towers each consisting of
eight fans, two cooling towers carry 27,500Cu m/h circulating water for condensers of one unit.

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1.5. Startup Boiler:
One startup boiler using diesel oil as fuel with steam output of 50t/h is provided to meet
steam requirement for initial start of unit as well as a backup of power plant auxiliaries. A separate
stack 30m high has been constructed for it.
1.6. Electrical Part:
The electricity generated at 15.75 KV is brought out from unit transformer at 220 KV and
fed to the national grid via a switch yard. Power plant auxiliaries are fed at 6.6 KV.

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2. Phase#02 (Units #05 & 06):
It consists of two units of 200MW each having equipment like phase#1. Turbines are
placed longitudinally in the main building outdoor boiler exhaust of two units connected to one
stack.
2.1. Overview:
There are many different types of power plants including thermal power plants and hydel
power plants. Thermal power plants use fuel such as gas, HSD, furnace oil or nuclear fuel to
produce heat energy that is converted to electrical energy through a series of intermediate
processes. Hydel power plants convert the potential energy of water to electrical power as it
follows from higher to lower elevations.
The "traditional" thermal power plant is the Rankin cycle plant named after the man who
invented the cycle. A power plant cycle is a series of processes in which a fluid, generally
water/steam, is used to convert heat energy to mechanical energy. The Rankin cycle in its simplest
form consists of a boiler, a turbine, a condenser and a boiler feed pump. Early plants had thermal
efficiencies of approximately 25% to 30%. Only 25% to 30% of the heat energy in the fuel burned
in these plants was converted to electrical energy. The rest was lost in various ways. The Rankin
cycle has been refined considerably over the years and made more efficient by the addition of
components like economizer, feed water heaters, super heaters and re-heaters. The efficiency of
Rankin cycle has also been improved by increasing the pressure and temperature of the cycle. The
laws of thermodynamics and considerations such as material limitation have prevented any
significant improvement sense then. Power plants commonly use heat rate to measure efficiency.

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3. Steam Turbine:
A turbine is used to convert heat energy into mechanical energy. The turbine used in T.P.S
MuzaffarGarh is an impulse-reaction steam turbine. The load requirement is controlled by the
steam flow through a governing valve. Maximum steam at full load is 670t/h. When the load at
generator is suddenly decreased then the rpm (frequency) of the generator is increased and to
decrease the frequency we lower down the steam flow which decreases the speed and maintains
the frequency.
If the load suddenly increased rotor speed becomes slower, to increase the speed, steam
flow is increased.
Steam turbine has three parts.
1. HP turbine
2. IP turbine
3. LP turbine

Figure 3: Turbine Hall

3.1. HP (High Pressure) Turbine:
First of all, steam from boiler comes into the HP turbine. Steam in the HP turbine is called
live steam or main steam. The rotor blades diameter of this part of turbine is smallest of the other
parts of the turbine. The inlet steam temperature of the HP turbine is 540°C and pressure is 130bar.
The outlet steam temperature of the HP turbine is 290°C and pressure is 15bar. HP turbine has a
total of 12 stages including one governing stage.
3.2. IP (Intermediate Pressure) Turbine:
Steam comes into IP turbine from HP turbine via re-heaters. The steam pressure in this
section of turbine is 14bar and temperature is 540°C. This part has a total of 10 pressure stages.
3.3. LP (Low Pressure) Turbine:
The outgoing steam of the IP turbine entered the LP turbine. Steam from the LP turbine
goes into the condenser.
Steam Turbine Specification:

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 Maximum load 210MW
Live steam pressure 132bar
Live steam temperature 540°C
Rated speed 3000rpm
HP cycle exhaust temperature 310°C
HP cycle exhaust pressure 24bar
Re-Heat steam temperature 540°C
Re-Heat steam pressure 14bar

3.4. Turbine Protection:

• Lube oil pressure (low & high)
• Vacuum drop
• Live steam temperature drops
• Axial shift displacement
• Gas cooling pump tripping
• HP heater level high
• All FWP trip high vibration tripping
• Trip unit by switch/emergency

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4. The Generator:
The generator is a device which converts mechanical energy into electrical energy.
4.1. Working Principle:
The working principle of generator is based on the Faraday's law of electromagnetic
induction, which states that:
"The electromotive force is always produced in conductor which is placed in the magnetic
field when there is a relative motion between conductor and the magnetic field".
If the output electrical energy is AC, it is called alternator. If the output electrical energy
is DC, it is called DC generator. In fact, there is no difference between alternator and Dc generator
except the way the output is obtained from the generator. In alternator the AC supply is produced
in the armature and supply is obtained through slip rings whereas in the DC generator are generated
AC supply is generated from the armature through the spilt rings or commutator which converts
the AC into DC. The following three things are necessary for generation of electrical energy.
1. Magnetic field
2. Conductor
3. Relative motion between conductor and magnetic field
In the small generator the magnetic field is being produced in the stator and the
electromotive force is produced in the rotor through Faraday's law of electromagnetic induction.
Electromagnetics are used in the generator to produce the magnetic field. In the large generator
the magnetic field is produced by the electromagnetic in the rotor and the electromagnetic force is
produced in the stator. the output is taken from the rotor, the rotor must
Have high insulation due to high voltage induction and it must have heavy insulation which
may increase the size of rotor, and require more power for the prime mover to rotate to this heavy
rotor:
1. Main Generator Parameter:
2. Pilot Exciter:
Type Tfy-46-500
Rated voltage 93/161V
Rated current 286/165A
Rated speed 3000rpm
Rated power factor 0.875
Phase 3
Rated frequency 50Hz

Armature connection
Specification - OEA.513.039
Manufacturing date - 1993-3-1
Rated capacity - 46KVA

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Alternating Exciter:
Type T1-1165-4
Rated voltage 431V
Rated current 1562A
Rated speed 3000rpm
Rated power factor 0.91
Phase= 3
Rated frequency= 100Hz

Armature connection
Specification OEA.513.039
Manufacturing date= 1993-8-24
Rated capacity - 1165KVA

4.2. Turbine Generator Water Hydrogen Cooled:

Specification OEA.512.137
Manufacturing date 1993-2
Type QFSN-210-2
Rated capacity 246MVA
Rated output 210MW
Rated voltage 15.75KV
Rated current 9056A
Rated speed 3000rpm
Rated frequency 50Hz
Phase 3
Connection of stator winding 2-Y
Power factor 0.85
Excitation current 18.67A
Maximum inlet water temperature for stator 50°C
winding
Maximum inlet cooling hydrogen 50°C
Excitation voltage 289V
Rate H2 pressure 0.3MPa
Water flow for stator winding 35m2/h
4.3. Cooling System of Turbo Generator:
The first question that arises here is why we need cooling of the generator? As the current
flows in the stator and rotor of the generator is very high so it increases the temperature of the
stator and rotor winding. As a result, the resistance of the stator and rotor windings increases which
increases the power losses and may cause the insulation breakdown.

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Two types of cooling are used in the turbo generator of TPS phase second.
• Stator cooling
• Rotor cooling
4.3.1. Stator Cooling:
The stator of the turbo generator is cooled by distillated or demineralized water. For this
purpose, a special plant is installed which prepares the demineralized water for the stator cooling.
This demi-water is also used for cooling system of the thirstier converts the water is passed through
the hollow conductor of stator winding for its cooling.
The demi-water is necessary for the cooling of the stator winding because raw water is not
a pure insulator which may cause the flow of leakage current when passed through stator winding.
The demi-water plant removes the impurities and minerals of the raw water and make it good
insulator whose resistivity is taken at a minimum level of 200K.cm. The demi-water that processes
through the stator winding absorbs the heat of stator winding makes it cool and becomes hot itself.
The demi-water then passes through heat exchanger (coolers) where its temperature is decreased
by the circulating water coming from the cooling towers. This demi-water is also passed through
the mechanical and magnetic filters before passing through stator winding and thirstier converts.
Water Parameters in Heat Exchangers:
Rated temperature of cooled water at inl 32°C
Minimum temperature of cold water 15°C
Number of gas heat exchangers 02
Rated water flow in on heat exchanger 150m3/h
4.3.2. Rotor Cooling:
The rotor cooling is done by H2 gas. Hydrogen is used for the following purposes:
1. Its heat exchange capability is much better than other gases.
2. It is much lighter than other gases so do not overload the rotor.
3. Its preparation is very easy and cheap.
Hydrogen gas is filled in the generator and maintained at a pressure of 4Kg/cm2. It takes
all the heat off the rotor and cools the rotor winding and gets warmed it. For the cooling of the gas
there are four gas coolers inside the generator on each corner. Circulating water of the cooling
tower is used in the gas cooler for hydrogen cooling.
Hydrogen gas is explosive if it is combined with oxygen under pressure so too avoid any
leakage of gas and entrance of air inside the generator the rotor assembly is sealed by the seal oil
whose pressure is at least 0.7Kg/cm2 more than hydrogen gas inside the generator.
When the generator is turned off for a long time for maintenance purpose hydrogen is
released from the generator in the air using a special method. Method involves that firstly fill the
generator with CO2 which releases the hydrogen in the air and then in the end air is filled in the
generator and CO2 is released in the air. This method is adopted because if hydrogen is released
using air instead of CO2, then it can cause an explosion due to oxygen in the air which will meet
hydrogen under pressure in the generator. After maintenance hydrogen gas is refilled in the
generator using the reverse process as described above.

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4.4. Water Parameters in Gas Cooler:
Rated temperature of cold water at inlet 32°C
Minimum temperature of cold water 15°C
Maximum water pressure 3Kg/cm2
Number of gas cooler 04
Rated water flow in on gas cooler 76.5m3/h

4.5. Protections of Generator:

The following protections are installed for the protection of the generator in TPS.
i) Longitudinal Differential Current Protection:
This system is intended to protect against multiphase short circuit in generator stator
winding and its leads including against double earth fault, one of which being the generator.
ii) Lateral Differential Current Protection:
This system is intended to protect against turn-to-turn short circuit of one phase in the
generator stator winding.
iii) Earth Fault Protection of Stator Winding:
This system is intended to reveal and disconnect one phase earth fault of generator stator
winding.
iv) Differential Protection of the Unit:
This system is intended to backup longitudinal differential protection of generator.
v) Negative Sequence Current Protection:
This system is intended to prevent damage of generator increase of overloading by negative
sequence current caused by asymmetric load or external asymmetric short circuit and abnormal
operating condition of power grid.
vi) Over Current Protection Against Overloading of Generator:
This system is intended for signaling at symmetric overloading of generator stator.
vii) Protection Against Asynchronous mode, when excitation loss:
This system is intended to protect against asynchronous mode. One of the elements of
resistance block relay for protection of the unit against external symmetrical short circuit used.
viii) Protection of Generator Rotor Against Overloading:
This system is intended to protect against overloading under emergency conditions as well
as increase of failure of generator excitation system which cause long term flow of current of
abnormal value along the rotor winding.
ix) Earth Fault Protection in One Point of excitation Circuit:
This system is intended to protect the generator in case of earth fault at one point of
excitation circuit.
x) Over Current Protection of Exciter Against External Short Circuit:
This system is intended to protect against overcurrent in the external system of the exciter.

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5. Boiler:
The boiler is the main part of any thermal power plant. It converts the fuel energy into
steam energy. The fuel may be furnace oil, diesel oil, natural gas or coal. The boiler may be fired
from multiple fuels. The type of boilers used in the T.P.S phase#2 is the "water tube type".

Figure 4: Unit 1 Boiler

5.1. Water Tube Boilers:
In water tube boilers, boiler water passes through the tubes while the exhaust gasses remain
in the shell side, passing over the tube surface, since tubes can typically withstand higher internal
pressure then the large chamber shell in a fire tube, water tube boilers are used where high steam
pressure (as high as 3,000Psi) are required.

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 Water tube boilers are also capable of high efficiencies and can generate saturated or
superheated steam. The ability of water tube boilers to generate superheated steam makes these
boilers particularly attractive in applications that require dry, high-pressure, high-energy steam,
including steam turbine power generation.
5.2. Boiler Parameter:

Rated evaporating amount 670t/h

Reheat steam amount 575.8t/h
Main steam pressure 140Kg/g
Temperature 540°C
Outlet pressure of reheat system 23.8 Kg/g
Outlet temperature of reheat system 540°C
Inlet pressure of reheat system 25.8 Kg/g
Inlet temperature of reheat system 310°C
Feed water temperature 250°C
Boiler efficiency (Burn oil) 90.26%
Boiler efficiency (Burn gas) 85%
Exit gas temperature (Burn oil) 153°C
Exit gas temperature (Burn gas) 136°C
Consumption of crude oil 48.2t/h
Consumption of natural gas 59650 N/h

5.3. Main Parts of Boiler:

The boiler consists of following main parts:
i) Burners
ii) Furnace
iii) Generation Tube
iv) Down Comer Tube
v) Water Tube
vi) Super Heater
vii) Re-Heater
viii) Air Pre-Heater
ix) Boiler Drum

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5.4. Boiler Drum:
A steam drum is a standard feature of a water-tube boiler. 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. It is installed at the top of the boiler. Boiler Drum
have 50% water level. It has 2 functions.
1. During unit starting boiler drum filled with water and water from boiler drum by gravity
come to generation tube.
2. After unit starting, by generation tubes the saturated steam shift to boiler drum, and the
steam or water are separated in boiler drum.
Parts of Boiler Drum:
1- Cyclone
2- Primary Separator
5.5. Air Pre-Heater:
The purpose of the air pre-heater is to recover heat from the boiler flue gas which increases
the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas. As a
consequence, the fuel gases are also sent to the fuel gas stack (or chimney) at a lower temperature,
allowing simplified design of the ducting and the flue gas stack. It also allows control over the
temperature of gases leaving the stack.
5.6. Economizer:
Flue gases from large boilers are typically 450-650°F. Stack economizer recover some of
this heat for pre-heating water. The water is most often used for boiler make-up water are some
other need that coincides with boiler operation. Stack economizers should be considered as an
efficiency measure when large amounts of make-up water are used (i.e., not all condensate is return
to the boiler or large amount of live steam are used in the process so there is no condensate to
return) or there is a simultaneous need for large quantity of hot water for some other use. The
savings potential is based on existing stack temperature, the volume of make-up water needed and
the hours of operation.
5.7. Furnace:
Furnaces heat air and distribute the heated air through the house using ducts. Boilers heat
water and provide either hot water or steam for heating. A furnace is a container or enclosed space
in which a very hot fire is made.
5.8. Burner:
The boiler burner provides the heat necessary for converting water in the boiler into steam and is
attached to the furnace of boiler. Each unit has 12 burners. All burners installed in sequence. 1 to 6 upward
and 7 to 12 downward.
5.9. Accessories of Boiler:
i) Force Draft Fan (FDF)
ii) Gas Recirculation Fan (GRCF)
iii) Induced Draft Fan (IDF)

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 iv) Chimney
v) Economizer
5.10. Force Draft Fan (FDF):
The force draft fan sucks the air from atmosphere which is used in the furnace for burning.
The air from the atmosphere is passed through the filter to remove the dust and other particles from
the air. The air from the FDF is then fed to the regenerative heaters.
The motor of FDF has following specification:
Type = KK 800 11-8
Rated voltage 6.6KV
Rated current 114/121.3A
Rated speed 747rpm
Output 1000KW
Rated frequency 50Hz
Power factor 0.81
Moment of inertia 310
Connection of stator/rotor Y
Permissible rise 80K
Ambient temperature 40°C
Weight 12020/13250 Kg
Degree of protection IP54
No. of phases 3

5.11. Induced Draft Fan (IDF):

ID fan sucks the flue gases from the boiler and exhaust through chimney.
The motor of ID fan has following specifications:
Type = KK 800 11-6
Rated voltage 6.6KV
Rated current 20A
Rated power 2000KW
Rated speed 991rpm
Insulation class F
Connection of stator winding 2Y
Permissible rise 80K
No. of phases 3
Ambient temperature 40°C
Rated frequency 50Hz
Moment of inertia 410
Degree of protection IP54
Weight 15970 Kg

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5.12. Gas recirculation fan (GRCF):
The motor of GRCF has the following specifications:
Type - KK 400 11-4
Rated voltage 6.6KV
Rated speed 1491rpm
Rated current 34A
Rated power 315KW
Connection of stator winding Y
Insulation class F
Permissible rise 70K
Ambient temperature 50°C
No. of phases 3
Rated frequency 50Hz
Degree of protection IP54
Moment of inertia 11.7
5.13. RAH:
Regenerating Air preheater is a heat exchanger. It is used to extract heat from the flue gas
and supply that heat energy to the atmospheric air that enters inside the boiler.
5.14. Calorifier:
It is heating exchanger. It is used to dry air and heat toward the boiler.

Figure 5: Accessories and Parts of Boiler Diagram

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5.15. Boiler Protection:
• Fuel Protection
• Gas Pressure Protection
• Diesel Oil Protection
• Furnace Oil Protection
• FD Fan Trip
• ID Fan Trip
• Regenerative Air Pre-Heating Trip
• Drum Level High
• Drum Level Low
• Re-Heat Steam Pressure Drop
• Furnace Pressure Low
• Furnace Flames Out
• Natural Gas Pressure High

22
6. Furnace Safeguard Supervisory System (FSSS):
The FSSS station consists of the following parts:
1. Decanting area
2. Fuel oil tank
3. First lift pump
4. Main heater
5. Second lift pump
6. Diesel pumps
7. Recirculation pumps
8. Recirculation heater
9. Filters
10. Control room

6.1. Decanting Area:

The furnace oil that is used as a fuel in the burners of the boiler furnace to produce the
steam is transported to the TPS through two ways:
1. Oil tankers
2. Train
For unloading of the fuel from oil tankers and train there is separate unloading or de-canting
station for each. The unloaded fuel oil is initially stored in the underground reservoir; from there
it is filled in the main storage tanks.
2 pumps are used to fill the main storage tanks from the oil tankers decanting area. One of
them is active (on load) and the other is standby.
6.2. Fuel Oil Tanks:
From the decanting area the furnace oil is filled in the storage tanks. From there it is
supplied to the burners of the boiler furnace after proper heating.
Usually, one storage tank is called a service tank, and from there furnace oil is supplied to
the units. The furnace oil is filled in the other tanks first and then filled in the service tank through
recirculation pumps (RCP). The oil in the tanks is kept heated at the temperature 75-80°C. There
is total 06 storage tanks for furnace oil each having a volume of 20,000 hence each can store
2,00,00,000 litter. There are two diesel oil storage tanks each having capacity of 1000ton.
6.3. First Lift Pump:
The first lift pump takes the furnace oil from the service tank and supplies it to the main
heaters. There is a total of 4 first lift pumps which are operated according to unit load conditions.
The specification of first lift pump motor is as follows:
3 Phase 50Hz induction motor:
Connection Star
Power 55KW
Power factor 0.9

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 Efficiency 90%
Voltage 230/400V
Speed 2950rpm
Current 177/102A

6.4. Main Heaters:

There are 04 main heaters each connected to the respective first lift pump. The main heaters
heat the furnace oil through the steam which comes from the boiler. Steam is used to heat the oil
in recirculation heaters. The steam follows through the pipes which heat the oil outside the tube.
The temperature and pressure of the steam in the main heater is:
Temperature = 270°C
Pressure= 11-13bar
6.5. Second lift Pump:
Second lift pumps take the furnace oil from the main heater and supply to boiler of the
units. There are 04 second lift pumps which are operated according to the unit load conditions.
The temperature of oil that is supplied to the boiler is 105-120°C.
The specification of second lift pump motor is as:
3 phase 50Hz induction motor:
• Power = 250KW
• Voltage = 6.6KV
• Speed = 2950rpm
• Current = 252A

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7. Cooling Towers:
Cooling towers are heat removal devices used to transform process waste heat to the
atmosphere. Cooling tower may either use the evaporation of water to remove process heat and
cool the working fluid to near the wet-bulb air temperature or rely solely on air to cool the working
fluid to dry –bulb air temperature. Common applications include cooling the circulating water used
in oil refiners, chemical plants and power stations.

Figure 6: Cooling Towers

7.1. Circulating water pump motor:
The motor of the CWP has following specification:
Stator voltage 6.6KV
Rated speed 372rpm
Rated current 182A
Rated power 1600KW
Connection of stator winding 2Y
Insulation class B
Ambient temperature 50°C
No. of phases 3
Rated frequency 50Hz
Degree of protection IP54
Weight 17500Kg

7.2. CW Pump:
Type is single stage double suction centrifugal pump.
Type - 1400S25-1
Capacity 16000/h
Speed 370rpm
Power 1600KW
Weight 35000Kg
Head 25m
NP SHR 8.5m

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8. Cycles:
8.1. Steam Cycle:
Generation tubes

Boiler Drum

Super Heater

Turbine HPC

For Reheat in Reheater

IPC

LPC

8.2. Feed water Cycle:

Feed tank

Feed Pump

HPH #5

HPH #6

HPH #7

Economizer

Boiler Drum

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8.3. Condenser Cycle:
Condenser

Hot Well

Condensate Pump

Vent

Steam Air Ejector

LPH #1

Gland Steam condenser

LPH #2

LPH # 3

LPH #4

Feed Tank/D7

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8.4. Fresh Air Cycle:
FD fan

Calorifier

RAH

Furnace
8.5. Flue Gases Cycle:

Furnace

RAH

ID-Fan

Chimney

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Conclusion:
The conclusion is that a thermal power station is a power plant in which the prime mover
is steam driven. Water is heated, turns into steam and spins a steam turbine which either drives an
electrical generator or does some other work, like ship propulsion. After it passes through the
turbine, the steam is condensed in a condenser and recycled to where it was heater, this is known
as a Rankine cycle. The greatest variation in the design of thermal power stations is due to the
different fuel sources. Some prefer to use the term energy center because such facilities convert
forms of heat energy into electrical energy.
Commercial electric utility power stations are usually constructed on a very large scale and
designed for continuous operation. Electric power plants typically use three phase or individual
phase electrical generators to produce alternating current (AC) electric power at a frequency of
50Hz or 60Hz depending on its location on the world. Other large companies or institutions may
have their own usually smaller power plants to supply heating or electricity to their facilities
especially if heat or stem is created anyway for other purposes.

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Acknowledgement:
First, we offer our deep gratitude to Almighty Allah, most merciful and gracious, who
blessed us knowledge and inspiration to accomplish desire goal.
We are grateful to acknowledge Honorable Teachers and Department of Mechanical Engineering
UET Lahore, Narowal Campus for providing us a chance of internship in Thermal Power Station
Muzaffargarh and for their kind support.
Secondly, we express our heartiest obligation and thanks to our internship report
supervisors, Sir Amanullah and Sir Javaid for their kind guidance and valuable suggestions.
Their patronizing attitude and support helped us in the completion of this internship. After that we
are thankful to all the technical assistants for their constant guidance during the preparation of the
report. They motivated us to do this task as a challenging opportunity so that we can become a
successful engineer of tomorrow.

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