Thapar Polytechnic College

G.N.D.T.P. Bathinda

INTRODUCTION

Guru Nanak Dev Thermal Power Plant is a coal-based plant. The requirement of coal for
four units based on specific fuel consumption of 0.60 kg / kWh. The conveying and
crushing system will have the same capacity as that of the unloading system. The coal
comes in as large pieces. This coal is fed to primary crushers, which reduce the size of
coal pieces from 400mm to 150mm. Then the coal is sent to secondary crusher through
forward conveyors where it is crushed from 150mm to 200mm as required at the mills.
Then the coal is sent to boilers with the help of primary fans. The coal is burnt in the
boiler. Boiler includes the pipes carrying water through them; heat produced from the
combustion of coal is used to convert water in pipes into steam. This steam generated is
used to run the turbine. When turbine rotates, the shaft of generator, which is
mechanically coupled to the shaft of turbine, gets rotated so, three phase electric supply is
produced.
The basic requirements are:

Fuel (coal)

Boiler

Steam turbine

Generator

Ash handling system

Unit auxiliaries

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BRIEF HISTORY
OF PLANT

Due to high rate of increasing population day by day, widening gap between power
demand and its availability was one the basic reason for envisaging the G.N.D.T.P. for the
state of Punjab. The other factors favoring the installation of the thermal power station
were low initial cost and comparatively less gestation period as compared to
hydroelectric generating stations. The foundation stone of G.N.D.T.P. at Bathinda was
laid on 19th November 1969, the auspicious occasion of 500th birth anniversary of great
Guru Nanak Dev Ji.

The historic town of Bathinda was selected for this first and prestigious thermal project of
the state due to its good railway connections for fast transportations of coal, availability
of canal water and proximity to load center.

The total installed capacity of the power station 440MW with four units of 110MW each.
The first unit of the plant was commissioned in September, 1974. Subsequently second,
third and fourth units started generation in September 1975, March 1978, and January
1979 respectively. The power available from this plant gives spin to the wheels of
industry and agricultural pumping sets.

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WORKING OF
THERMAL PLANT

Coal received from collieries in the rail wagon is mechanically unloaded by

Wagon Tippler and carried by belt Conveyor System Boiler Raw Coal Bunkers after
crushing in the coal crusher. The crushed coal when not required for Raw Coal Bunker is
carried to the coal storage area through belt conveyor. The raw coal feeder regulates the
quantity of coal from coal bunker to the coal mill, where the coal is pulverized to a fine
powder. The pulverized coal is then sucked by the vapour fan and finally stored in
pulverized coal bunkers. The pulverized coal is then pushed to boiler furnace with the
help of hot air steam supplied by primary air fan. The coal being in pulverized state gets
burnt immediately in the boiler furnace, which is comprised of water tube wall all around
through which water circulates. The water gets converted into steam by heat released by
the combustion of fuel in the furnace. The air required for the combustion if coal is
supplied by forced draught fan. This air is however heated by the outgoing flue gases in
the air heaters before entering the furnace.
The products of combustion in the furnace are the flue gases and the ash. About
20% of the ash falls in the bottom ash hopper of the boiler and is periodically removed
mechanically. The remaining ash carried by the flue gases, is separated in the electrostatic
precipitators and further disposed off in the ash damping area. The cleaner flue gases are
let off to atmosphere through the chimney by induced draught fan.
The chemically treated water running through the water walls of boiler furnace
gets evaporated at high temperature into steam by absorption of furnace heat. The steam
is further heated in the super heater. The dry steam at high temperature is then led to the
turbine comprising of three cylinders. The thermal energy of this steam is utilized in
turbine for rotating its shaft at high speed. The steam discharged from high pressure
(H.P.) turbine is returned to boiler Reheater for heating it once again before passing it into
the medium pressure (M.P.) turbine. The steam is then let to the coupled to turbine shaft
is the rotor of the generator, which produces electricity. The power from the generator is
pumped into power grid system through the generator transformer by stepping up the
voltage.
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The steam after doing the useful work in turbine is condensed to water
in the condenser for recycling in the boiler. The water is pumped to
deaerator from the condenser by the condensate extraction pumps after being
heated in the low pressure heater (L.P.H) from the deaerator, a hot water
storage tank. The boiler feed pump discharge feed water to boiler at the
economizer by the hot flue gases leaving the boiler, before entering the
boiler drum to which the water walls and super heater of boiler are
connected.
The condenser is having a large number of brass tubes through which
the cold water is circulated continuously for condensing the steam passing
out sides the surface of the brass tubes, which has discharged down by
circulating it through the cooling tower shell. The natural draught of cold air
is created in the cooling tower, cools the water fall in the sump and is then
recirculated by circulating water pumps to the condenser.

A Pleasant view of G.N.D.T.P. Bathinda

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GENERAL DESCRIPTION

BOILER FEED PUMP:As the heart is to human body, so is the boiler feed pump to the steam power plant. It is
used for recycling feed water into the boiler at a high pressure for reconversion into
steam. Two nos. 100% duty, barrel design, horizontal, centrifugal multistage feed pumps
with hydraulic coupling are provided for each unit. This is the largest auxiliary of the
power plant driven by 3500 KW electric motor.
The capacity of each boiler at GURU NANAK DEV THERMAL PLANT is
375 tones/hr. The pump which supplies feed water to the boiler is named as boiler feed
pump. This is the largest auxiliary in the unit with 100% capacity which takes suction of
feed water from feed water tank and supplies to the boiler drum after preheating the same
in HP-1, HP-2 and economizer. The delivery capacity of each boiler feed pump is 445
tones/hr. to meet better requirements corresponding to the various loads, to control steam
temperature, boiler make up water etc. The detailed particulars checking of protections
and inter locks, starting permission etc. are as below:-

Particulars of BFP and its main motor:-

BOILER FEED PUMP:- The 110 MW turboset is provided with two boiler
feed pumps, each of 100% of total quantity. It is of barrel design and is of
horizontal arrangement, driven by an electric motor through a hydraulic coupling.

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Type

200 KHI

No. of stages

Delivery capacity

445 t/hr.

Feed water temperature

158C

Speed

4500 rpm

Pressure at suction

8.30 kg/cm

Stuffing box

mechanical seal

Lubrication of pump

oil under pressure

And motor bearing supplied

hydraulic coupling

Consumption of cooling water

230 L/min.

WATER TREATMENT PLANT:The water before it can be used in the boiler has to be chemically treated, since untreated
water results in scale formation in the boiler tubes especially at high pressure and
temperatures. The water is demineralised by Ion Exchange Process. The water treatment
plant has production capacity of 1800 Tonnes per day for meeting the make-up water
requirement of the power station.

COAL MILL:Coal Mill pulverizes the raw coal into a fine powder before it is burnt in the boiler
furnace. The pulverizing of coal is achieved with the impact of falling steel balls,
weighing 52.5 tonnes, contained in the mill drum rotating at a slow speed of 17.5 r.p.m.

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The raw coal is dried, before pulverizing, with inert hot flue gases tapped from the boiler.
Three coal mills each with a pulverizing capacity of 27 T/hr. are provided for one unit.

INDUCED DRAUGHT FAN:Two nos. axial flow Induced Draught Fans are provided for each unit to exhaust ash laden
flue gases from boiler furnace through dust extraction equipment and to chimney. The fan
is driven by an electric motor through a flexible coupling and is equipped with remote
controlled regulating vanes to balance draught conditions in the furnace. The fan is
designed to handle hot flue gases with a small percentage of abrasive particles in
suspension.

CONTROL ROOM:The control room is the operational nerve center of the power plant. The performance of
all the equipments of the plant is constantly monitored here with the help of
sophisticated instrumentation and controllers. Any adverse deviation in the parameters of
various systems is immediately indicated by visual and audio warning and suitable
corrective action is taken, accordingly. The control room is air conditioned to maintain
the desired temperature for proper functioning of the instruments.

SWITCH YARD:Electricity generated at 11 KV by the turbo-set is stepped-up by unit transformers to

132/220 KV for further transmission through high tension lines to Maur, Muktsar,
Malout, N.F.L., Sangrur and Ludhiana. Transmission of power to grid is controlled
through 7 nos. 220 KV and 15 nos. 132 KV. Air Blast Circuit Breakers along with their
associated protective systems.

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WAGON TIPPLER:The coal received from the collieries, in more than 100 rail wagons a day, is unloaded
mechanically by two nos. wagon tipplers out of which one serves as a standby. Each
loaded wagon is emptied by tippling it in the underground coal hopper from where the
coal is carried by conveyor to the crusher house. Arrangements have been provided for
weighing each rail wagon before and after tippling. Each tippler is capable of unloading
6-8 rail wagons of 55 tonnes capacity in an hour.

WAGON TIPPLER

CIRCULATING WATER PUMP:Two nos. of circulating water pumps provided for each unit, circulate water at the rate of
17200 T/hr. in a closed cycle comprising of Turbine Condenser and Cooling Tower. An
additional Circulating Water Pump provided serves by for two units. The water
requirement for bearing cooling of all the plant auxiliaries is also catered by these pumps.

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CRUSHER HOUSE:Coal unloaded by the wagon tippler is carried to crusher house through conveyors
for crushing. Two nos. hammer type coal crushers are provided, which can crush
coal to a size of 10 mm. The crushed coal is then supplied to Boiler Raw Coal
Bunkers. The surplus coal is carried to coal storage area by series of conveyors.
Crushing of coal is an essential requirement for its optimum pulverizing and safe
storage.

CRUSHER HOUSE

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COOLING TOWERS:Cooling Towers of the power plant are the land mark of the Bathinda City even for a far
distance of 8-10 kilometers. One cooling tower is provided for each unit for cooling
18000 tones of water per hour by 10C. cooling towers are massive Ferro-concrete
structure having hyperbolic profile creating natural draught of air responsible for
achieving the cooling effect. Cooling tower is as high as 40 storey building.

COOLING TOWER

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BOILER:It is a single drum, balanced draught, natural circulation, reheat type, vertical combustion
chamber consists of seamless steel tubes on all its sides through which water circulates
and is converted into steam with the combustion of fuel. The temperature inside the
furnace where the fuel is burnt is of the order of 1500C. The entire boiler structure is of
42 meters height.

BOILER

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BOILER CHIMNEY:The flue from the boiler, after removal of ash in the precipitators, are let off to
atmosphere through boiler chimney, a tall ferro-concrete structure standing as high as the
historic Qutab Minar. Four chimneys, one for each unit, are installed. The chimney is
lined with fire bricks for protection of ferro-concrete against hot flue gases. A protective
coating of acid resistant paint is applied outside on its top 10 meters.

BOILER CHIMNEY

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COAL MILLING PLANT

Since G.N.D.T.P. units are primarily coal fired units so each boiler is provided with
closed milling circuits to pulverize the raw coal which is received from coal conveying
system after coal crushes before it is fired in the furnace. The necessity of pulverizing the
coal is to be ensuring its maximum possible combustion in the furnace. The coal data for
units are: -

COAL DATA

UNITS 1 & 2

UNITS 3 & 4

Bituminous

Bituminous

4300 Kcal/kg

4727 Kcal/Kg

Type of Coal
Net Calorific Value
Moisture

10 %

7.5 %

Ash Content

30 %

32 %

24 %

27 %

10 mm

20 mm

Volatile
Incombustible

Matter

Inlet of Coal

Raw coal of maximum size 10 mm 20 mm is pulverized in the milling

circuit and the output from the mill is fine coal. Milling circuits of the
following main constituents: -

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1. Raw Coal Bunkers (R.C. Bunkers).

2. Raw Coal Chain Feeders.
3. Drum Mill or Coal Mill.
4. Classifiers.
5. Cyclone Separator.
6. Vapors Fan.
7. Pulverized Coal Bunkers (P.C. Bunkers).

COAL MILL

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RAW COAL BUNKER:Each of three raw coal bunkers is fabricated from the sheet metal and is well stiffened all
around. The storage capacity of each raw coal bunker is about 500 tones. There are four
outlet gates with each bunker. The gates are electrically operated from site. In case of
failure of the electric motors the gate can be hand operated from site. At a time only one
gate opening is suffices but should be changed so that there is no pilling within the
bunker.

RAW COAL CHAIN FEEDER:The raw coal chain feeder transports coal from raw coal bunker to the inlet chute leading
to the pulverized/coal mills. There is a double link chain of high tensile strength steel,
which moves on wheels and sweeps the raw coal falling over the top of the raw coal
chute of the mill. The height of the coal bed in the chain feeder can be adjusted manually
by means of lever operated damper. The maximum and minimum heights of the coal bed
are 200mm and 120mm respectively. The signaling equipment indicates the absence of
coal flow in the feeder, which is annunciated in the unit control board (U.C.B.). The main
shaft on the driving end is connected to the driving unit, consisting of variator, a gear box
and a motor all mounted as a single unit. The chain wheel on the driving end shaft is
provided with a shear pin, which will shear off and disconnect the driving mechanism if
there is any overload on the feeder. The speed of the chain feeder is regulated
automatically/remotely by actuating the control spindle of the variator through a
servomotor. A pump for circulating the oil in the gear box of variator is an integral part of
variator driven by a separator motor. Some of the technical data about the raw coal chain
feeder is given here:-

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1. Output of the chain feeder

10-45 tonnes/hr.

2. Speed variations

0.0503-0.151m/sec.

3. Main motor

7.5kW, 415V, 50Hz.

4. Oil pump motor

0.05kW, 220V

5. Operating motor of each gate

3HP, 415V and 50Hz.

RCCF

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DRUM MILL:Each mill consists of single compartment drum, bearings driving motor, coal inlet and
discharge piping, ball change and lubricating equipment for mill bearings. Mill drum is
fabricated from thick steel plates and is supported on to the anti-friction bearings. The
mill is driven by an electric motor of capacity 630kW, 990 rpm, 6.6kV through a
reduction gear, which reduces the speed to 17.5 rpm. The ball charge for the mill consists
of the three different sizes of forged steel balls detailed as below. The capacity of each
mill is 27 T/hr. in case of unit 1 & 2 and 28 T/hr.

DRUM MILL

CLASSIFIER:The classifier is fabricated from the steel plates. It is an equipment that separates fine
pulverized coal from the coarser pieces. The pulverized coal along with the carrying as
well as drying medium (flue gas) strikes the impact plate in the classifier and the coarser
pieces get separated due to the change in the direction of flow and go back to mill. The
stream then passes to the outlet branch of the classifier through an adjustable telescopic
tube. At the outlet adjustable vanes are provided to change the size of coal when required.

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CYCLONE SEPARATOR:The centrifugal type cyclone separator consists of two cyclones made up of welded
sheets. It is equipment in the milling plant, which serves for separating the pulverized
coal from the vapours i.e. carrying medium. The pulverized coal gets stored in the
pulverized coal bunkers and vapours go to suction of vapour fan. At the bottom of the
cyclone separator a rotary valve (Turnikete) is provided to transport coal from cyclone
separator to P.C. bunker on the worm conveyor as the case may be.

VAPOUR FAN:Pulverized coal bunker is welded from thick steel sheets and has a capacity of 4 hours
coal consumption at maximum continuous rating of the boiler. The whole bunker is
insulated externally. The carbon-dioxide blanketing system has been provided in the P.C.
bunker to prevent fire hazards inside the bunker. The while storage bunker is divide into
four parts namely A, B C & D. Further four coal feeders are taken out from each bunker
leading to each corner of the furnace.

CRUSHING OF COAL:When coal reaches the plant, normal size of coal is about 500mm. After unloading the
coal from the rake is fed to primary crusher, which reduces the size to 120mm. Then coal
is fed to secondary crusher which reduces the size to 25mm and this coal goes to bunker
with the help of conveyor belt from where coal finally goes to coal mill where coal is
transferred in form of pulverized coal. The coal is heated with the help of hot primary air.
We maintain the temperature of about 70C in coal mill. This temperature is maintained
with the help of cold air and a hot air damper.

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Ball Mills:

G.N.D.T.P. Bathinda

-In Ball Mills there are steel balls which are revolving in horizontal

cylindrical drum. These balls are free from any shaft and balls are touching with each
other and with internal body of drum. These types of mills are at Bathinda Thermal Plant.
On the other hand, bowl mills part of the mill contain drive system i.e. it contains 6.6 kV
electric motor and gear system which translates the revolution about horizontal axis to
revolve about vertical axis. The revolving vertical axis contains a bowl about the driving
system. This bowl is fixed with driving and revolving with shaft. There are also three
rollers which are suspended at some inclination, so that there is a gap of few mm between
roller surface. These rollers are free to rotate about the axis.

Bowl Mills: - The coal is grinded and then fed into the mill at the center or near of
revolving bowl. It passes between the grinding ring in revolving bowl and rolls as
centrifugal force causes the material to travel towards the out perimeter of bowl. The
springs, which load the rolls, impart the necessary force for grinding. The partially
pulverized coal continue going up and down and over the edge of bowl.

BOWL MILLS
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COAL HANDLING PLANT

(CHP)

The G.N.D.T.P. units are primarily coal-fired units and the coal consumption at
maximum continuous rating (M.C.R.) per unit is about 58 T/Hr. the coal used at
G.N.D.T.P. is of bituminous and sub-bituminous type and this is received from some
collieries of M.P. and Bihar. The designed composition of coal is as below: Type

Bituminous Coal

Net calorific value

4300 kcal/kg

Moisture content in coal

10%

Ash content

30%

Volatile matter in combustibles

24%

Grind ability index

50 Hard Groove

The coal handling plant at G.N.D.T.P. has been supplied and erected by M/s Elecon
Engineering Company Limited, Vallabh Vidya Nagar, Gujarat. Coal is transported from
the coal mines to the plant site by Railways. Generally, the raw coal comes by railway
wagons of either eight wheels weighing about 75 to 80 tones each or four wheels
weighing about 35 to 40 tones each. The loaded wagon rake is brought by railways main
line loco and left on one of the loaded wagon tracks in the power station marshaling yard.
The main line loco escapes through the engine track. The station marshaling yard is
provided with 8 tracks. The arrangement of the tracks in the marshaling yard is as
follows:-

DESTINATION

NO. OF TRACKS

Loaded wagons receiving tracks

Four

Empty wagon standing tracks

Three

Engine escape tracks

One

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UNLOADING OF COAL:In order to unload coal from the wagons, two Roadside Tipplers of Elecon make
are provided. Each is capable of unloading 12 open type of wagons per hour. Normally
one tippler will be in operation while the other will be standby. The loaded wagons are
brought to the tippler side by the loco shunters. Then with the help of inhaul beetle one
wagon is brought on the tippler table. The wagon is then tilted upside down and emptied
in the hopper down below. The emptied wagon comes back to the tippler table and the
outhaul beetle handles the empty wagons on the discharge side of the tippler. The tippler
is equipped with the integral weighbridge machine. This machine consists of a set of
weighing levers centrally disposed relative to tippler. The rail platform rests on the
weighing girders and free from rest of the tippler when the wagon is being weighed. After
weighing the loaded wagons is tipped and returned empty to the weighing girders and
again weighed. Thus the difference of the gross weight and the tare weight gives the
weight of the wagon contents. The tipplers are run by motors of 80 H.P. each through
gears only.

UNLOAADING OF COAL

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WAGON TIPPLER
The tippler is designed to work on the following cycle of operation:Tipping

90 seconds

Pause

5-12 seconds

Return

90 seconds

Weighing

30 seconds

Total

215-222 seconds

Allowing 85 seconds for wagon changing it will be seen that 12 eight-wheel wagons or
24 four-wheel wagons per hours can be tipped. However since the coal carrying capacity
is 500 tones per hour load of 12 wagons comes to 8 to 9 per hour.

DUST TRAPPING SYSTEM:The tippler is also provided with the dust trapping systems by which the dust nuisance
will be minimized. As the tippler rotates, a normally closed hopper valve opens
automatically and the discharged material passes through it into the hopper with its dustsetting chamber, there is an air valve of large area, which opens, simultaneously with the
hopper valve. The object of this air valve is to blow back through the hopper valve into
the tipping chamber, which must occur if, the settling chamber were closed, it being
remembered that a large wagon contains some 240 cubic feet of material and that this
volume of dust air would be forced back at each tip if the hopper chamber were a closed
bottle. The air valve and the hopper valve are shut immediately on reversal of the tippler
and are kept shut at all times except during the actual discharge. The hopper valve is
operated by a motor of 10 H.P., 415 Volts and the air valve is operated by electrohydraulic thruster. Inlet valve consists of large number of plates sliding under the wagon
tippler grating. Coal in the wagon tippler hopper forms the heap and as such obstructs the
movement of sliding valve and damaging the plates. The inlet and outlet valves have
therefore been bypassed.
The unloaded material falls into the wagon tippler hopper (common to both
tipplers) having a capacity of 210 tones. The hopper has been provided with a grating of
300mm X 300mm size at the top so as to large size boulders getting into the coal stream.
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There is also a provision of unloading the wagons manually into the MANUALLY
UNLOADED HOPPER of 110 tones capacity. Manually unloading will be restored to
while unloading coal from sick wagons or closed wagons.

MAGNETIC PULLEYS:On belt conveyor no. 4A and 4B, there have been provided high intensity
electromagnetic pulleys for separating out tramp iron particles/pieces from the main
stream of coal conveying. D.C. supply for the magnet is taken on 415 volt, 3 phase, 50
cycles A.C. supply system.
In addition to above high intensity suspension type electromagnets have also been
provided on belt conveyors 4A and 4B for separating out tramp iron pieces/particles.

RECLAIMING:If the receipt of coal on any day more than the requirement of the boilers, the
balanced material will be stocked via conveyor 7Aand 7B and through telescopic chute
fitted at the end of the conveyor. At the end of the chute one tele level switch is provided,
which automatically lifts the telescopic chute to a predetermined height every time. The
tele level switch is actuated by the coal pile. When the telescopic chute reaches maximum
height during operation, which will be cut off by limit, switch and stop the conveying
system. When the pile under the telescopic chute is cleared, the telescopic chute can be
independently lower manually by push buttons.
There are five bulldozers to spread and compact the coal pile. Bulldozers of Bharat Earth
Movers Limited Make are fitted with 250 H.P. diesel engines. Each bulldozer is able to
spread the crushed coal at the rate of 250 tones/hr. over a load distance of 60m the coal
can be stacked to a height of 6m the stockpile stores coal for about 45 days for four units
with an annual load factor of 0.66.
Whenever coal is to be reclaimed the bulldozers are employed to push the coal in
the reclaim hopper having a capacity of 110 tones. The coal from the reclaim hopper is
fed either 9A or 9B belt conveyor through vibratory feeders 8A and 8B.

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CRUSHER HOUSE:The crusher house accommodates the discharge ends of the conveyor 4A, 4B receiving
ends of conveyor 5A, 5B and conveyor 7A and 7B, two crushers, vibrating feeders and
necessary chute work. There are two crushers each driven by 700H.P. electric motor, 3
phase, 50 cycles and 6.6 kV supply. The maximum size of the crushed coal is 10mm. The
capacity of each crusher is 500 tones/hr. one crusher works at a time and the other is
standby. From the crusher the coal can be fed either to the conveyors 5A, 5B or 7A, 7B
by adjusting the flap provided for this purpose. There is built in arrangement of bypassing
the crusher by which the coal can be fed directly to the conveyors bypassing crusher.

CONVEYOR BELT AND CRUSHER HOUSE

ELECTROSTATIC PRECIPITATIOR
(ESP)
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ELECTROSTATIC PRECIPITATOR
Dust extractions from industrial gases become a necessity for environmental
reasons. Most of the plants in India use coal as fuel for generating steam. The
exhaust gases contain large amount of smoke and dust, which are being emitted
into atmosphere. This poses a real threat to the mankind as a health hazards. Hence
it has become necessary to free the exhaust gases from smoke and dust.

Working Principle: -

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The Electrostatic precipitator utilizes electrostatic forces to separate the dust particle
form the gas to be cleaned. The gas is conducted to a chamber containing Curtains of
vertical steel plates. These curtains divide the chamber into a number of parallel gas
passages. The frames are linked to each other to form a rigid framework. The entire
framework is held in place by four supports insulators, which insulates it electrically from
all parts, which are grounded. A high voltage DC is applied between the framework and
the ground thereby creating a strong electrical field between the wires in the framework
and the steel curtains. The electrical field becomes strongest near the surface of the wire,
so strong that an electrical discharges. The Corona discharge is developed along the
wires. The gas is ionized in the corona discharge and large quantities of positive
andnegative ions are formed. The positive wires are immediately attracted towards the
negative wires by strength of the field induced. The negative ions however have to travel
the entire space between the electrodes to reach the positive curtains. On routes towards
the steel curtains the ions collide with each other and get charged and also this charge is
transferred to the particles in the gas. The particles thereby become electrically charged
and also begin to travel in the same direction as the ions towards the steel curtains. The
electrical force on each particle becomes much greater than gravitational force. The speed
of migration towards the steel curtains is therefore much greater than the speed of
sedimentation in free fall.

ESP

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BOILER SECTION

G.N.D.T.P. Bathinda

The steam generating unit is designed to meet the nominal requirements of 110MW turbo
generator set. The unit is designed for a maximum continuous rating of 375 tones/hr. at a
pressure of 139kg/cm2 and a steam temperature of 5400C. the reheated steam flows at
MCR 32H tones/hr. at the feed water temp at MCR is 2400C. The unit is a balance
draught dry bottom; single drum natural circulation, vertical water tube type, construction
with skin casing and a single reheat system. The furnace is arranged for dry ash discharge
and is fitted with burners located at the four corners. Each corner burner comprises coal,
vapour oil and secondary air compartments. The unit is provided with three ball mills and
arranged to operate with intermediate cool powder bunker. The steam super heater
consists of 4 stages Viz. Ceiling, convection, platen and final superheated. The ceiling
super-heated forms the roof of the furnace and horizontal pass and finishes as the rear
wall of the second pass. The convection super-heated is made up of horizontal banks
located in the second pass. While the platens are located at the furnace exit, the portion
above the furnace nose encloses the final superheated reheater are in two stages, first
stage is the triflux heat exchangers located in the second pass, which absorbs heat from
superheated steam as well as from the flue gases. The second stage is exit reheater
located in the horizontal pass as pendant tubular loops.

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(a) The flue gas for drying the cool in the mills is tapped off after the triflux heat
exchangers. The damper located in the hot flue gases pipe leading to mill controls the
quantity. Control the circulating vapour of the mill entry effect temperature control.
Immediately after the triflux heat exchanger, the air heaters and economizers are located.
The air heater is in 2 stages.
(b) The hot air for combustion from air heater stage 2 is led into the common wind box
located on the sided of the furnace. 4 cool air mixed pipes from pulverized coal bounders
are connected to 4 cool burners nozzle at the corners. There will be totally 16 coal
nozzles. 4 located in each corner. Oil guns will be located in the secondary air nozzle for
coal burning. The turn down ratio of the guns will be so selected that it will be possible to
use them also for pulverized fuels flame stabilization while operating under load below
the control point.
(c) Take into consideration the high % age of ash and the relatively poor quality of coal
due regards has been paid to wide pitching the tubes and to the gas velocity across the
heating surface areas. In order to insure reliable and continuous operation sample sot
blowing equipment is provided. There are short retractable steam root blowers provide at
the top of furnace fully retractable rotary type blowers are located for cleaning of the
secondary super heater and final heater partly retractable steam blowers are arranged for
the horizontal reheater and super heaters in the second pass. The steam root blowers are
electrically operated.
(d) Root blowing nozzles using blow down from boilers drum are provide for the
cleaning of areas around the burners nozzles zone for dislodging of slag boulder if any in
the bottom ash hopper in the furnace.
(e) Two FD fans are provided per boiler. The FD fans are of the axial type driven by
constant speed motor. The regulation of quantity and pressure is done by inlet vane
control. The flue gases are sucked through the mechanical and electrostatic precipitators
by I.D. fans and delivered into the chimney. Two I.D. fans are provided for each boiler

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and they are of the axial type driven by constant speed motors. Inlet vane control effects
the capacity change with reference to load. Both the I.D. and FD fans have been
dimensioned taking into account the minimum margins of 15% on volume and 32% on
pressure.

BRIEF IMAGE OF BOILER

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Specification

Manufacturer

B.H.E.L

Maximum continuous rating

375tones/hr.

Super heater outlet pressure

139kg /cm2

Reheater outlet pressure

33.8 kg/cm2

Final super heater temperature

540 deg.c

Feed water temperature

240deg.c

Efficiency

86% (stage-1)
87% (stage-2)

Coal consumption per day

1500 tones

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TURBINE SECTON
The turbine is the prime mover for the generator in the power plant Different
types of steam turbines used in thermal power plants, but the ones. Which
are used at G.N.D.T. P. are categorized as follows
S.No.

Type of Turbine

Turbine at G.N.D.T.P.

1.

Horizontal/vertical

Horizontal

2.

Single/multi cylinder

Multi cylinder

3.

Condensing/non condensing

condensing

4.

Reheat/ non-reheat

Reheat

5.

Regenerative/non regenerative

Regenerative

6.

With by pas/without by pass

Without

BASIC WORKING OF TURBINE:First of all the turbine is run on gear motor with the help of exciter. At that time steam is
kept on recirculating with the help of by-pass valve. When the pressure of steam is
increased to on optimum level and turbine acquires a particular rpm then steam is
introduced in the H.P. (high-pressure) cylinder first. The temperature of steam at entrance
is 540C and pressure is about 139 Kg/cm2. After doing its work on the H.P. Turbine, the
steam is taken out for reheating rated temperature of steam at reheater inlet is 360C. The
temperature of steam is increased upto 535C in the boiler shell and steam is again
introduced in M.P (Medium pressure) turbine. After M.P.turbine, the steam is passed on
to L.P. (Low-pressure) turbine. This process helps the
turbine to reach the speed of 3000 rpm. After L.P. turbine, the steam is condensed in
condenser, build below the turbine unit. The condenser contains a number of brass tubes
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through which cooling out from L.P. turbine it comes in contact with colder brass tubes
then steam get transformed into water. This water get collected in HOT WELL just below
the condenser. From here the hot water is again pumped with the help of condensate
pumps. The cooling water is used to condense steam gets heated up and is cooled by
falling from cooling tower. This completes the processing of steam through turbine and
condenser.

ROTOR OF TURBINE
The speed of whole system of rotor lies in the following ranges of the speed at the
operating conditions: 1900 to 2000 rpm Best noticed on the M.P. and L.P. rotors and generators.
2350 rpm Best noticed on H.P. rotor.

MAIN TECHNICAL DATA ABOUT TURBINE

The Basic Parameters

Rated output measured at terminal of the generator.

110,000KW

Economical output.

95,000KW

Rated speed

3,000 RPM

Rated temp. Of steam just before the stop valve.

535C

Max temp. Of steam before the stop valve

545C

Rated pressure of steam before the MP casing

31.63 ata

Max. Pressure of steam before the MP casing

35 ata

Rated temp. Of steam before the MP casing

535C

Max. Temp. of steam before the MP casing

545C

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System of turbine

Governing valves

2 interceptor valves

HP cylinder

2 Row Curtis wheel +8 moving wheels.

Wt. of HP rotor is approx.

5,5000kg.

MP cylinder

12 moving wheels.

Wt. Of MP rotor is approx.

11,000kg

LP cylinder

4 Moving wheels of double flow design.

Wt. of MP rotor is approx.

24,000.

Direction of the turbine rotation is to the right when looking at the turbine from the
front bearing pedestal.

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