Project Report

G.H.T.
P LEHRA MOHABBAT
PROJECT REPORT ON
SIX MONTHS INDUSTRIAL TRAINING REPORT
AT
Guru Hargobind Thermal Plant

LehraMohabbat, BATHINDA
Submitted in partial fulfillment of the requirements for the award of degree of
BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING
SUBMITTED TO :-SUBMITTED BY :-
Dr. BALWINDER SINGHVIVEK KUMAR
90311125963
5989ME/2K9
PTU GZS CAMPUS,

BATHINDA
ACKNOWLEDGEMENT
We take this opportunity to express our gratitude to our project guide, training manager
and esteemed personality Dr.Balwinder Singh under whose expert guidance we

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G.H.T.P LEHRA MOHABBAT
completed our project successfully. We are grateful for his encouragement, valuable
suggestions and guidance. He provided us with valuable tips and solutions to our
repeatedly occurring problems. Our sincere, effective and deep gratitude is due to him
for his excellent spirit, effective guidance, which gave us the confidence to complete the
work of training and project work.
We are also thankful to the Technical Training Cell (T.T.C) at
G.H.T.P.LehraMohabbat, Bathinda who introduced us to the problem and provided
us with valuable data, without which our project could not come to an existence. They
were instrumental in providing us with various lines to think on.
We are also thankful to our friends and class mates for their constructive criticism. They
helped us a lot in completing our project successfully.
CONTENTS
1. INTRODUCTION ....4
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2. COMPANY PROFILE...
9
3. PLANT
OVERVIEW..12
4. COAL HANDLING
PLANT..18
5. WATER TREATMENT .
.32
6. BOILER..36
7. FANS.......46
8. GENERATOR..60
9. TURBINE....64
10. ELECTROSTATIC
PRECIPITATOR..78
11. ASH HANDLING
PLANT....85
12. CONCLUSION.
88
13. BIBLIOGRAPHY
...89
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INTRODUCTION
BRIEF HISTORY OF PLANT
Ever widening gap between the power and its availability in the state of Punjab was one
of the basic reasons for envisaging the thermal plant at LehraMohabbat Distt.
Bathinda. The other factors favouring the installation of this thermal were low initial
cost and less generation period as compared to hydroelectric generating stations, its
good connection for fast proximity to load center. Guru Hargobind Thermal Plant is
Government undertaking (under P.S.E.B.)
Initially it was going to set up at Bathinda under GNDTP but the air force
personal restricted its set up at Bathinda hence plant site is shifted to LehraMohabbat
about 22km from Bathinda city. Latrr this plant was approved as aseparate autonomous
body with its name as Guru Hargobind Thermal Plant
GURU HARGOBIND THERMAL PLANT

LehraMohabbat, Distt. Bathinda (Punjab)
Guru Hargobind Thermal Plant is the third and the latest of the thermal plants of Punjab
State Power Corporation Limited and is located 23 km short of Bathinda on National
High Way No. 64 and is situated opposite Village LehraMohabbat. Total plant area is
1025 Acres. Basic fuel is coal and furnace oil. Stage-I consists of two units of 210MW
each. Stage-II consists of two units of 250 MW each. GHTP LehraMohabbat comprises
of two stages. Unit-1 & 2 of stage-I were synchronized on 29-12-97 & 16-10-98 and the
units started commercial operation w.e.f. 26-6-99 and 4-1-99 respectively. Unit-3 & 4 of
stage-II are generating electricity w.e.f 05.02.2008 & 11.10.2008 and these units started
commercial operation w.e.f. 16.10.2008 & 25.01.2010 respectively. GHTP has
surpassed its own records of highest generation during previous four successive years
and is being operated at the lowest cost of generation amongst all PSPCL power plants
despite having higher interest and depreciation. This plant has shown excellent
performance and huge savings have been made in terms of earning incentives by
performing better than PSERC targets through meticulous planning.
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During 2009-10, GHTP LehraMohabbat known for its performance has surpassed
another milestone by generating 75152 Lac units (Including 14729 Lac Units
generated by Unit-4 during stabilization period before its commercial operation)
against the target of 65790 Lac units set by Central Electricity Authority, New
Delhi. The plant load factor of 96.44% for commercial operation is the highest ever
plant load factor in PSPCL. The plant has surpassed its own previous highest record
of 95.10% plant load factor achieved during the year 2007-08. This plant load
factor of 96.44% achieved during 2009-10 is even higher than the plant load
factor of 95.99% which was achieved by GHTP Stage-I units and was the highest
amongst all state sector power plants during 2008-09.
The plant utilization factor of GHTP remained more than 100% at an ever highest value
of 100.38% during 2009-10. The auxiliary consumption during this year
remained at its lowest ever value of 8.23% against a PSERC target of 9.00%, thus
savingCrores of rupees, which speaks of high plant performance at which the
plant is being operated. The oil consumption remained at 0.373 ml/ kWh against
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the set target of 1.0ml/kWh.
GHTP has achieved the highest ever monthly generation of 7065 Lakh units at a
plant load factor of 103.21% during March 2010 which is highest ever monthly
plant load factor at any plant of PSPCL.
GHTP Unit 1 has run continuously from 28.02.2009 to 12.09.2009 (195.4 days)
without any interruption. This is a new record of longest continuous run by any unit
of PSPCL.
The relentless pursuit of excellence has helped to make GHTP a trend-setter, leader and
a light house in Punjab State Power Corporation Limited by achieving high
plant performance and economy. GHTP has taken a lead in cutting down its capital
overhauling period from traditional practice of 45 days to as low as 28.5 days and
annual overhauling period from 20 days to less than 14 days resulting into savings
ofCrores of rupees by PSPCL in terms of purchase of power. This had been possible
due to lust of excelling continuously prevailing amongst GHTP engineers and staff.
In the year 2009-10, annual maintenances of unit no. 1 & 2 were carried out in less
than 29 days against approved shut down period of 40 days. The units were brought
on bar 11.12 days ahead of schedule; thereby an extra generation of 560 Lac units
savingRs. 30 Crores approx. was done in terms of power purchase.
The new records set by GHTP LehraMohabbat during 2009-10 are as

under:
Annual plant load factor: 96.44%Better than the All India
State Sector
National highest 95.99%
achieved by GHTP Stage-I
units during 2008-09.
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2009-10 Previous Record
(Actual)
Highest ever annual generation: 7515.2 MU 5610.09MU in 2008-09
Highest ever annual plant load factor:96.44% 95.10% in 2007-08
Highest ever annual plant utilization factor: 100.38% 100.31% in 2007-08
Highest ever annual deemed plant load factor: 97.53%97.07% in2003-04
Lowest ever annual Auxiliary Cons. (%):8.23%8.71% in2008-09
Plant performance and energy consumption:

Sr. Operating Unit 2006-07 2007-08 2008-09 2009-10
No. parameters
1 Actual Gen. MU 3443.172 3508.587 4441.92 6042.262
2 Plant Avail. Factor % 94.33 94.81 95.98 96.07
3 Plant Utilization % 99.21 100.31 98.86 100.38
factor
4 Plant load factor % 93.58 95.10 94.89 96.44
5 Deemed PLF % 95.31 95.65 96.05 97.53
6 Auxiliary % 8.80 8.87 8.71 8.23
Consumption
7 Sp. Coal Kg/kWh 0.551 0.589 0.601 0.601
Consumption
8 Sp. Oil ml/kWh 0.327 0.228 0.802 0.367
Consumption
9 Heat Rate Kcal/kWh 2440 2446 2459 2421
10 Thermal Efficiency % 35.25 35.15 34.97 35.52
Energy Conservation
The following benefits have been accrued to GHTP as a result of implementation of
innovations / best practices to improve the energy efficiency of GHTP:
GHTP has achieved thermal efficiency of 35.52% during 2009-10 against a
target of 34.40% set up by Punjab State Electricity Regulatory Commission.
Auxiliary consumption of GHTP remained at its lowest ever value of 8.23%.
At GHTP, differential pressure across feed control valves of Boiler feed pump
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has been reduced from its normal value of 6.0Kg/cm2 to 0.4Kg/cm2. This has
resulted in reduction of nearly 13 Amperes of current on 6.6 KV on each running
BFP.
One no. CW pump of 975 KW for Unit 1 & 2 is being stopped in winter by
running 3 no. CW pumps in parallel for two units against normal running of 2
no. CW pumps for each unit separately.
Two no. TACW pumps of 110 KW each are being stopped in winter by running
one no. TACW pump against normal running of 2 no. TACW pumps for each
unit.
As DM water make up is very low, so one no. hot well make up pump has been
put into operation for two units against running of one no. separate pump for
each unit.
125 Watt Mercury vapour lamps have been replaced with 70 watt Sodium
vapour lamp, wherever possible.
The deviation in all the parameters affecting efficiency of the plant have been
made available online to the operators. Alarm signals are generated in all such
cases to take corrective actions by the operator.
Start up of auxiliaries has been optimized.
Providing energy efficient PA fans during erection of GHTP Stage-II units.
Providing VFDs on ID fans during erection of GHTP Stage-II units.
GHTP has declared its Energy Management Policy as under:
COMPANY PROFILE:-
STAGE -1:-
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1) Name of the Project Guru Hargobind Thermal Plant Stage-I
2) Location
LehraMohabbat, Distt. Bhatinda
3) Installed Capacity unitwise 2 x 210 =420 MW
4) Type of Fuel
Coal
5) Executing Agency TATA HONFY WELL AND BHEL
6) Clearances Status Cleared by CEA, New Delhi. Investment

approved by Planning Commission.All
clearance obtained.
7) Total estimated Cost
Rs. 1200 Crores.(approx.)
8) Synchronization dates Unit-1 : DECEMBER 1997

Unit-2 : AUGUST 1998
9) Annual Generation at 68.5% 3000 MU 2715 MU Net

load factor
10) Coal consumption / year

1860000 Ton
11) Cost of Generation 112 Paisa/Kw
STAGE -2:-
1) Name of the Project
Guru Hargobind Thermal Plant Stage-II
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2) Location LehraMohabbat, Distt. Bhatinda
3) Installed Capacity unitwise 2 x 250 = 500 MW
4) Type of Fuel Coal
5) Executing Agency BHEL
6) Clearances Status Cleared by CEA, New Delhi. Investment

approved by Planning Commission.All
clearance obtained.
7) Total estimated Cost Rs. 2123 Crores.(approx.)
8) Synchronization dates Unit-3 Commercial Operation date (COD)16-

10-08
Unit-4 COD expected on dated 31-01-09
9) Annual Generation at 3000 MU 2715 MU Net
68.5% load factor
10) Coal consumption / year 1860000 Ton
11) Cost of Generation Rs. 3.17 ( at Bus Bar).
ELECRICITY GENERATION PROCESS EXPLANATION

The coal travels by the conveyer belts from the coal handling plant to the
coalbunkers from where it is fed into pulverizing mills; which grind the coal into
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powder. The powder coal is carried from the mill by steam of air heated air in the air
heated driven by primary air fan (PA) to boiler burners where it is blown into the
furnance and burns like a gas a force draft fan provide addition controllable to the
burners to assist combustion. The product of this combustion is dust and ash. (Ratio of 5
to 1) the ash to the bottom of the boiler and is periodically sluiced to mash setting pits.
The dust carried in the fuel gas to the precipitators where it is extracted by high voltage
electrodes. The dust is then conveyed by settling lagoons or removed by the road for
safe. Fuels gas passes by an induced draft fan (ID) to the chimney. The heated air in the
air heater driven by primary air fan (PA) to boiler burners where it is blown into the
furnance and burns like a gas a force draft fan provide addition controllable to the
burners to assist combustion. The product of this combustion is dust and ash. (Ratio of 5
to 1) the ash to the bottom of the boiler and is periodically sluiced to mesh setting pits.
The dust carried in the fuel gas to the precipitators where it is extracted by high voltage
electrodes. The dust is then conveyed to setting lagoons or removed by the road for safe.
The fuel gas passes by an induced daft fan (ID) to the chimney. The heat released by the
burning coal is absorbed by long length of tubing which form the boiler valves. Inside
the tube extremely pure water that is known boiler feed water is converted by the heat
into steam at high pressure and temperature. The is then superheated in further tubes
and passes to the high pressure (H.P) turbine where it is discharged through the nozzle
into the turbine blades. The energy of the steam striking the blades make the turbine
rotates after passing through the high-pressure turbine. The steam is returned to the
boiler for reheating before passing through the intermediate pressure turbine (IPT) and
to the low pressure turbine (LP). Coupled to the turbine shaft is rotor of the generator, a
large cylindrical electromagnet, so that when the turbine rotor rotates, other rotor rotates
whit it. The generator rotor is enclosed in the stator, which consist of large coils copper
bar in which electricity is produced by the rotation of magnetic field created by the
rotor. The electricity from the stator winding goes to a transformer, which increase its
voltage so that it can be transmitted over the power lines into grid system. Mean while,
the steam that is exhausted its useful energy in turning the turbine is turned back into
water in the condenser so that it can be used again in the boiler. Before entering in the
boiler at the economizer the water is pumped by condense extract pumps heated in the
low pressure (LP) heaters, deaerated in the deaerator increased in the pressure by boiler
feed pumps and heated further in high presser (HP) heaters. The water passes through
the economizer to the stem drum then up through the furnace wall-tubing before
returning to the steam drum for steam separation. The steam leaves the drum and heated
further in the super heater on its way to HP Turbine. The condenser contains miles of
tubings through which the cold water is constantly pumped.
PLANT OVERVIEW
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BLOCKS DISCRIPTION
SUPERHEATER (SH)
Super Heater (SH) is a plain tubular, non-drainable vertical in line spaced type, arranged
for parallel flow. This super heater (SH) is located in the horizontal path after reheater.
Next to Super Heater is Reheater System.
REHEATER SYSEM (RH)

The reheater section is the single stage, spaced type, continuous loop, and plain tubular,
non-drainable, vertical in line spaced type, arranged for parallel flow.
ECONOMISER SYSTEM (ECON)

The economizer system is a single block unit, is of continuous loop plain tubular,
drainable horizontal, in line arrangement with water flow upwards and gases flow
downwards. The economizer tubes are suspended from economizer intermediate header,
using ladder type supports.
DEAERATOR (DEA)
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The deaerator (DEA) is provided to remove dissolved corrosive gases from feed water
that goes to the boiler. It prevents internal corrosion of boiler tubes. The oxygen is
reduced to untraceable limits by mechanical means in the condense living the deaerator.
BOILER FEED PUMP (BFP)

Boiler feed pump (BFP) is very important auxiliary of the powerhouse. It has to take
supply of water from the powerhouse. It has to take supply of water from the deaertor,
and supply it to boiler drum against the positive drum pressure.
MILLS
Bowl mills have been installed from pulverizing the raw coal. The coal of minimum
size of 25 mm is received in raw coalbunkers from coal handling plant. From the
bunker, this coal is fed into the mill through Raw Coal Feeder. Regulating the speed of
the Feeder can control the feed of the coal mill.
CODENSER (COND)
The condenser (COND) is a box type double pass with divided water box design that
facilitates the operation of one half of the condenser while the other half is under
maintenance. The steam space is of rectangular cross section to achieve optimum
utilization of the enclosed volume for necessary air-cooling section at the center from
where air and non-condensable gases are drawn out with the help of air evacuation
pumps. The circulating water enters the water boxes from bottom and then travels
through several tubes and leaves the condenser through upper water boxes in two
distinct paths. Next to condenser is condensate extraction pump (CEP).
CONDESATE EXTRACTION PUMP (CEP)

There are two 100% capacity condensate extraction pumps (CEPs) provided in the
system. Normally, one condensate extraction pump runs and other is kept as stand-by.
These pumps are of vertical and centrifugal canister type with the driving motor.
Condensate extraction pumps have five stage.
GLAND STEAM COOLER (GSC)

The gland steam cooler is used to condense the system extracted from turbine glands
and to maintain slight vacuum at the turbine glands to avoid steam leakage to
atmosphere from turbine glands. It is a single pass heat exchanger with the main
condensate entering from one end and leaving from the other end. Air steam mixture
passes over the tubes in zigzag path due to number of baffles and thus steam condensed
there-by heating the condensate inside the tubes.
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DRAIN COOLER (DRN CLR)

Drain cooler (DRN CLR) is provided to sub cooler the drains coming from pressure
(LP) Heater to improve the cycle efficiency by heating up the condensate flowing
through the tube system.
LP HEATERS (LP HTRS)

The LP heaters (LP HTRS) are of the surface cooled type. They are designed for vertical
mounting. These heaters are of tube system withdrawal type, these are of four-pass
design. Condensate flows inside the tube while steam flows outside the tubes. The
condensed steam is collected in the bottom of the shell that is drained out.
H.P. HEATER (HP HTRS)

High pressure heater is supplied heating steam from extraction 5 taken from IP casing of
turbine. The feed water enters first in this H.P. heater and after getting heated goes to
High pressure (HP) heater 6. The feed water flows through the tubes from coldest zone
to the hot most zones before it leaves the heater. The steam flows from most zones to
coldest zone and drain normally goes to deaerator.
ROTARY AIR HEATER (RAH)

The basic principal of operation of Rotatary Air Heater (RAH) is the same as the liung
storm type except that the elements are stationary and the air hoods rotate with. In the
gas pass at approximately 1 rev./min. The axis of rotation may be vertical or horizontal
but again and for similar reasons the vertical spindle is preferred. The drive is normally
through an electric motor operating a pinion that meshes with the rack on the outer rim
of the hood assembly.
FORCED DRAFT FANS (FD FAN)

To take air from atmosphere at ambient temp. To supply essentially all the combustion,
air can either be seized to overcome all the boilers losses (pressurized system) or just
put the air in the furnace (balanced draft units).
INDUCED DRAFT FANS (ID FANS)

Used only in balanced draft units to suck the gases out of the furnace and throw them
into the stack. Handles fly ash laden gases at temperature of 125 to 250 C.
ELECTROSTATIC PRECIPETATORS (ESP)
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The principles upon which Electrostatic Precipitators operates are that the dust-laden
gases pass into a chamber where the individual particles of dust are given an electric
charge by absorption of free from a high voltage DC ionizing field. There are four
different steps in the precipitation viz., ionization of gases and charging of dust
particles, migration of the particle to the collector, deposition of charged particles on the
collection surface, dislodging of particles from the collection surface.
POWER DISTRIBUTION
Electric Power Generated here is send to various sectors through distribution center.
This is the main product of the plant, which is our nations wide requirement. Electric
power drives all our factories, industries, Railways, Domestic equipment etc. Overall
our life is dependent on the electric power now days
Disributioncenter distributes from here to Barnala Sub Distribution Mansa, Bathinda,

Delhi, Ludhiana and Duri as per requirements.
RAW MATTERIAL AND THEIR SOURCES

Power gen eration is using coal, HFS etc. as burning fuels for the generation of steam
from demineralised water.
Coal coming from West Bangal& Bihar via Rail wagon of 3800 Kcal/kg & 35% ash
contents as the minimum requirement with rate of rupees 680/-p.tone. &4000 Tons per
Day in quantity.
Water is taken from Sirhand canal by the tunnel link of underground

2600mm dia pipes, which is collected in water pond of 150 arcs area & capacity 100000
cubic meters.
The power availability from the plant now meets 20-25% O of the total power
requirement in Punjab. It has gone a long way in ushering prosperity in the state by
emerging a large number of agricultural pumping sets, more increased employment
potential reliability and improvement in continuity of supply and system and removal of
power cuts to a great extent. It has also led fast development of environment in area
around District Bathinda by providing employment to about 3000 persons. Two new
units of 250MW each are going to be commissioned soon, sanctioning of which has
already boing done.
COAL HANDLING PLANT
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In G.H.T.P., the main fuel is COAL. It is burnt to get the thermal energy, which is used
to convert water into steam. This energy is released by the combustion of certain
chemicals (e.g. carbon, hydrogen etc.) present in coal with oxygen.
The various types of fuels in steam thermal plants used are: solid fuels (coal, coke),
liquid fuel (petrol, diesel), gas fuel (natural gas, biogas). In steam thermal plants, the
selection of a particular type of fuel is a problem of economics. However in G.H.T.P.,
coal is used.
COAL AND ITS SELECTION: Coal is a general term that encompasses large organic
minerals with widely differing compositions and properties, although all are essentially
rich in amorphous elemental carbon. The main types of coal are:
1. Peat
2. Lignite
3. Sub-bituminous
4. Bituminous
5. Semi- bituminous
6. Anthracite
7. Super-anthracite.
In India, coal is present in large quantities. The main mines of coal in India are in
The main companies, which provide coal to the Plant, are:
The coal is sent by one or more of these companies by railway transportation. In plant,
the properties of coal are examined by chemical methods. Main methods are:
1. Proximate analysis
2. Ultimate analysis.
Proximate analysis gives the principal characteristics of the coal, whereas ultimate
analysis gives its chemical composition. On the basis of the properties of coal studied,
coal is ranked as per standards maintained.
Then payment of coal is done on the basis of rank observed by the Punjab State
Electricity Board to the concerned companies.
The coal should have the following properties:

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1. Low Moisture Content
2. Low Ash Content
3. Low Volatile Matter
4. Low Sulphur Content
5. Low Hydrogen
6. High Carbon Content.
COAL HANDLING PLANT
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In G.H.T.P., coal handling is done mechanically instead of manually, due to following
reasons:
1. Large quantity of Coal has to be handled everyday,
2. Reliability of mechanical devices,
3. Mechanical handling is cheaper one,
4. Unloading of Coal from rail wagons is difficult and time consuming by manual
handling,
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.
MAJOR PARTS
In G.H.T.P., the main parts are divided into two parts:
1.General Working Parts,
2.Emergency Working Parts.
General Working Parts are:

1. Wagon Tippler
2. Junction Tower
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3. Primary crusher
4. Secondary crusher
5. Bunkers
6. Conveyer System
Emergency Working Parts are:

1. Stacker cum Reclaimer
2. Manual Handling Hopper
3. Emergency Reclaimer Hopper
PULVERIZED COAL: The coal available is not in suitable form it is present in pieces
of average size 50 to 100 mm. These pieces cannot be used in Furnace directly. The
reason is that its surface area is not so enough to combust it fully and properly. As
surface area of coal increases, it catches fire very easily and soon
The main advantages of using pulverized are given below:

Surface area is increased, hence combustion is completed.
Coal is dried effectively
No/reduced clinkers formed
Efficiency increases as complete combustion.
Easy transportation of coal into furnace.
Hence we have to convert the pieces of coal into pulverized coal to take the advantages
of it. For this in G.H.T.P. two types of crushers has been used to convert the bigger coal
pieces into smaller ones. Then these pieces are converted into pulverized (powder) form
with the help of mills (known as PULVERIZER). These crushers and mills are:
1 PRIMARY CRUSHER
2 SECONDARY CRUSHER
3 BOWL MILLS.
Name of equipment Type No.

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Primary Crusher Rotary crusher 2
Secondary Crusher Ring granulator 2
Pulverizer Bowl mill 6 (for each unit)
PRIMARY CRUSHER: It is a type of crusher used to break the bigger pieces into
smaller ones. There are TWO Primary Crushers PC A and PC B. The purpose of having
two is to have uninterrupted crushing of coal. Suppose one P.C. breaks down during
crushing, then at the same time the other is started. Meanwhile the first one is
undergone repair and maintenance, thus making it ready for further operation.
When one is working the other is kept always ready for meeting emergencies. These are
used shift by shift. One is working in day sift and remains at maintenance and is ready
for working in next shift. Main parts of it are:
1. CASING
2. PERFORATED CYLINDER
3. LIFTER SHELVES
4. MOTOR DRIVE SYSTEM
PURPOSE OF PC:The main purposes are:
To break the bigger pieces into smaller ones

To reject the foreign particles and the coal pieces which do not break in PC.
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WORKING OF PRIMARY CRUSHER:This crusher s composed of a large cylinder.
It consists of a large no of holes on its surface area. The diameter of these holes has
been varied along the periphery. Some initial rows have the holes of dia 25cm, next
ones have the holedia of 20 mm, and others have holedia 15mm. On the inner periphery
of cylinder lifting shelves are attached. The cylinder rotates at a small speed of 20rev
per min. The cylinder receives the coal feed at motor drive side. The smaller pieces
(Dia<25mm) directly falls from holes. The lifting shelves lift the bigger ones. When
shelves go on top, the coal pieces falls down and break and pass through the holes. This
procedure continues until the pieces are broken down. Although there are some pieces,
those do not break, are lifted by shelves ad are thrown in rejection duct.
SECONDARY CRUSHER:In this crusher, the coal pieces coming from P.C. are
further crushed. The size of coal pieces is reduced from 25mm to 10-15mm. Like P.C.,
there are two no of S.C. SC A and SC B. The type of S.C. is RING GRANULATOR.
The purpose of having two is to have uninterrupted crushing of coal. Suppose one S.C.
breaks down during crushing, then at the same time the other is started. Meanwhile the
first one is undergone repair and maintenance, thus making it ready for further
operation.
When one is working the other is kept always ready for meeting emergencies. These are
used shift by shift. One is working in day sift and remains at maintenance and is ready
for working in next shift. Main parts of it are:
1. HAMMERS (LOOSE RINGS )

2. VIBERATING SCREEN
3. SCREEN BAR( PERFORATED PLATES )
4. MOTOR DRIVE SYSTEM
5. SHAFT
6. PRESSURE PLATES
WORKING OF SC:The coal coming from Primary Crusher is fed in VIBERATING

SCREEN. The Vibrating Screen separates the fine coal dust particles from the coal
pieces. The coal dust falls down. The coal pieces are allowed to fall in casing of SC.
Here the main Shaft is rotated at a normal speed of 100-130 rpm. On this shaft,
hammers are mounted. These are the loose rings made of cast iron. Here are five sets of
loose ring rod. On each rod there are 15 loose rings. As shaft rotates, the hammers, due
to Centrifugal forces, tend to come outside. The coal pieces now come between two
surfaces. One is of hammers and other is of pressure plate. As there is very small gap (of
10mm) between two surfaces, the coal is broken. Now this crushed coal is fallen down
on the conveyors and is sent further.
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CONVEYING SYSTEM:-
The coal received in the tippler hopper is fed to either or both the
conveyors no. 2A and 2B through water discharging mouthpieces integral with the
electromagnetic vibrating feeder 1A and 2B and flap gates. Either or both conveyors 2A
and 2B running underground will also be fed from manual unloading hopper
through mouthpieces integral with rack and pinion operated gates, electromagnetic
vibrating feeders 3A and 3B and flap gates. Coal will also be fed either of the conveyors
2A or 2B from either of conveyors 9A or 9B running completely underground, which in
turn receive coal from reclaim hopper from coal storage area through mouthpieces
integral with the rack and pinion gates, electromagnetic feeders 8A and 8B and flap
gates. The conveyors 2A and 2B will feed coal to either or both the conveyors 4A and
4B at the underground transfer point through flap gate. The inclined conveyors 4A and
4B, which are partially underground will feed coal via magnetic pulleys to either or both
crusher A and B through electromagnet vibrating feeder 10A and 10B, the iron particles
separated by magnetic pulleys 4A and 4B are collected on the crusher house ground
floor through a long chute provided in the crusher house.
CONVEYOR SYSTEM
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BELT CONVEYORS:-
Belt conveyors in the coal handling system are occupying an outstanding

position. In addition to their primary use, as a mean of transporting coal from unloading
stations and/or from coal yard to raw coal bunkers they also perform numerous other
functions such as weighing, stocking and removing of tramp iron particles/pieces. The
belting is of rubber and canvass type having suitable number of skim-coated piles. The
details of belts of various conveyors are given at next page.
S.No. Approx. Width No. of Thickne H.P. of

Convey Length(m (mm) Piles ss driving
or m) (mm) motor
1. 2A,2B 81500 1050/10 7 19 40
67
2. 4A,4B 183150 1050/10 7 19 20
67
3. 5A,5B 182400 1050/10 6 19 20
67
4. 6A,6B 105400 900/914 5 17 40
5. 7A,7B 222500 900/914 5 13 60
6. 9A,9B 115000 900/914 5 13 40
The belting is of Dunlop/Goodyear/Hilton make. The capacity of each belt is 500-

tones/hr. the belt speed is approx. 2.5 m/sec. The belts run on idlers spaced at
convenient distances. At the end there are end pulleys and on one end are driven by
electric motors. There are three rollers on each carrying idler and one roller on each
return idler. At the coal transfer points impact, idlers have been provided. To align the
belt, self-aligning, carrying and return idlers have been provided at about 15 meters
from each terminal or bend pulley and approx. 24 meters thereafter. Grease nipples have
been provided with all the idlers. The idlers near the suspension magnet are of non-
Page | 23
magnetic material.Automatic gravity operated tensioning arrangement has been
provided for all conveyors, which takes up stretch in each belt while starting under load
giving a constant slack side tension. The tensioning arrangement comprises of take up
pulley, bend pulley, weight box. Suitable sliding gear and counter weights.For cleaning
upper and internal surfaces of the belt, for increasing the belt conveyor components life,
two belt cleaners with each conveyor have been provided, one for cleaning upper part of
the belt called external belt cleaner and other for cleaning the internal surface of the belt
called internal belt cleaner. All the conveyors have been accommodated on frame works
comprising of gantries, trestles, belt covering and walkways etc. outdoor portions of all
the conveyors have been provided with belt covering of galvanized corrugated sheets
and rolled sheets sections. Grating walkways of about 120mm width with suitable
handrails have been provided for all the conveyors for operation and maintenance
purposes. Pull wire switches are mounted on the walkway side of each conveyor at
about 30m intervals. These switches are connected by a pull wire, which is easily
accessible from any position and runs along the entire length of the conveyor. In case of
emergency, operation pulls the chain and stops the system.The run of the conveyor belt
is monitored by Belt Way Switches, which cut off the main circuit in the event of an
eccentric run of the belt.Zero speed switches are also named as the Belt Sequence
Switches have been provided on the return roller of the belt for the correct operation of
the conveyor belt. The rotation of the roller is transmitted by a shaft to the actual
monitoring element with a micro switch.
The zero speed switch provides the following functions:
The switch operates in conjunction with a time delay to determine whether a

conveyor belt reaches its normal speed within a specified period. The subsequent
drive can be switched only after the monitor belt had reached its normal speed.
The switch cuts of the drive, if it has not run up to the normal speed within a
certain time.
The switch trips the motor contractor in case of excessive fall of speed/breaking
of belt.
Page | 24
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.
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
feedersand 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.
COAL MILLING:-
Since G.N.D.T.P. units are primarily coal-fired units so each boiler is provided
with three 50% capacity identical closed milling circuits to pulverize the raw coal,
which is received from the coal conveying system after coal crusher before it is fired
in the furnace. The necessity of pulverizing the coal is to ensure the maximum possible
combustion in the furnace. The milling units have been supplied by B.H.E.L.
Page | 25
COAL MILL
The raw coal of maximum size 10-20mm is pulverized in the milling circuit and the
output from the mill is coal of fitness 20-24% remainder with sieve R-90. Milling
circuit mainly consists of the following main constituents:-
Raw coal bunker
Raw coal chain feeder
Drum mill
Classifier
Cyclone separator
Vapour fan
Pulverized coal bunker
Worm conveyor
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
Page | 26
a time only one gate opening is suffices but should be changed so that there is no pilling
within the bunker.
RAW COAL 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 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
CHAIN FEEDER
Page | 27
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:-
Output of the chain feeder 10-45 tonnes/hr.

Speed variations 0.0503-0.151m/sec.
Main motor 7.5kW, 415V, 50Hz.
Oil pump motor 0.05kW, 220V
Operating motor of each gate 3HP, 415V and 50Hz.
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.
1. 40mm diameter 22500 kg

2. 50mm diameter 20000kg
3. 60mm diameter 10000kg
4. Total Ball Charge 52500kg
Page | 28
During operation only 60mm diameter balls are added is approx. 500 kg per week and
the guiding factor is the amperage of the coal mill, normally it should be 66-ampere
approx. at full load and when it falls below the above value ball charging of the mill is
carried out. Lubricating system consists of the oil tank, gear pump, oil cooler and base
frame to mount all these equipments. Gear pump is driven by an electric motor of rating
1 H.P., 415 V, 1440 rpm. Suction side of the gear pump is connected to the tube oil tank
and the delivery side is connected to inlet of the oil cooler and after cooling oil goes to
the bearings. The oil from the bearings is cooled to the required temperature in the
cooler by the means of plant bearing cooler water.
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.
COAL FEEDING AND COAL MILL:-
From the coal handling plant, coal comes in two belts namely 5A and 5B and then by
belts 6A and 6B coal comes in bunkers. Bunker capacity is 300 tonnes. Number of
outlets of bunker is three. First gate is opened for one hour and second and then third. If
open the one gate for long time, then coal will stop going to mill. That is why we open
the gate turn by turn.
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 vapors i.e. carrying medium. The pulverized coal gets stored in
the pulverized coal bunkers and vapors go to suction of vapor fan. At the bottom of the
Page | 29
cyclone separator a rotary valve (Tunicate) is provided to transport coal from cyclone
separator to P.C. bunker on the worm conveyor as the case may be.
CYCLONE SEPARATOR
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.
USE OF OIL:-
Before the coal reaches the furnace, we preheat the furnace in order to remove the
moisture and raise the temperature of furnace, so that coal can catch fire easily without
any delay. This preheating of furnace is done with the help of oil. With burning of oil,
we maintain the temperature of furnace at 350C. we cut the oil supply after 350 C
because oil is very costly. Source of oil for G.N.D.T.P., Bathinda is Mathura Oil
Page | 30
Refinery. Other use of oil is in bearing system for cooling. There are large number of
bearings for plant. For example bearing system of turbine. These bearings get heated
upto high temperature, which is dangerous. So we cool the bearing by circulating water
in bearing.
COAL MILL:-
These are mainly of two types:-
i) Ball Mills
ii) Bowl Mills
Ball Mills:-
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.
Page | 31
WATER TREATRMENT
The water is required for two purposes at GURU NANAK DEV THERMAL POWER
PLANT:-
For Boiler feed makeup taken from D.M. plant
A. Cooling tower makeupPortablewater,Service water and other requirement
B. For fire protection total hourly requirement of 1 unit of 110MW is nearly 1200
m/hr.
SOURCE OF RAW WATER:-The source of raw water for the plant isSirhind canal or
river water. It contains impurities like Calcium, Magnesium salts, Silica suspended
solids and minerals to a 300-500 ppm during monsoon period and a normal supply has
200-300 ppm.
Hardness of water indicates calcium and magnesium salts present in water. Bicarbonates
and carbonates of these salts constitute temporary hardness sulphates, nitrates chlorides
etc. constitute permanent hardness. These cause scale formation in boiler.
To avoid the deposition of scale on metal surfaces, corrosion of boiler tube metal
etc. difficulties, water treatment process is used. This knows the impurities of water as
External water treatment
Internal water treatment
REMOVAL OF TURBIDITY/ SUSPENDED PARTICLES:-
Suspended particles are coarse which settle rapidly if enough retention time is provided.
Turbidity comprises of negatively charged particles and hence remains in a colloidal
form. To remove this a coagulant is added to the water to produce positively charged
particles which would attract the negative particles, which will form flows, and will
settle easily. The equipment performing these activities is called a clarifier. It removes
solid particles and suspended particles.
Chlorination of water is also done to destroy fungi and bacteria.
REMOVAL OF DISSOLVED SALTS:- This process is called the Deminerilisation

process and is performed in D.M. plant. This basically consists of two units in series.
One is called cation Exchange unit and other anion exchange unit. The cation exchange
is filled with cation resin which exchanges hydrogen ion in the resin for all cations.
Page | 32
Similarly anion exchanger has anion resin which exchanges OH ion for all anions. The
result is pure water. Let take dissolved impurity of calcium sulphate.
In cation exchange unit:-
CaSO4 + H2(Z) (cation resin) H2SO4 + Ca(Z) (calcium salt)
In anion resin:-
H2SO4 + Z(OH)2 (anion resin) ZSO4 (sulphate) + 2H2O (pure water)
There for in reaction (1), CaSO4 has been converted to H2SO4 and in second stage the
same H2SO4 is converted to water i.e. after some time the resin become ineffective due
to saturation of exchange sides of resins with ions and these are regenerated with acid
and alkali to bring them back to original conditions reactions are as below:-
Ca(Z) + 2HCl CaCl2 + H2(Z) (cation resin)
Z(SO4) + 2NaOH Z(OH)2 (anion resin) + Na2SO4
The impurities like Na2SO4 and CaCl2 formed are discharged to waste, the
combination of cation and anion units produce pure water. After this water is passed
through Mixed Bed Unit which has both cation and anion exchanger throughly mixed.
The result is water of very high purity.
From cation exchanger, it contains weak and unstable acids like carbonic acid in
addition to stable acids like H2SO4, HCl. Since conversion of water based acid into
anion unit is costly process there for weak acid unstable acids can be removed by
passing through degassifier which decompose them
H2CO3 H2O + CO2
Sometimes Sodium Sulphate dosing is done to filter water.
INTERNAL WATER TREATMENT: -
Regard less of purity of water obtained from internal treatment which is chemical
process, is required for complete protection against scale, corrosion Phosphate dosing.
Page | 33
Calcium carbonate in the drum will react with tri-sidium phosphate, forming calcium
tri-phosphate which can be removed by blow down of drum water. Thus scaling is
avoided.
Ca(HCO3)2 CaCO3 + H2O + CO2
Further Na3PO4 dosing helps in maintaining alkalinity in boiler drum which is

neccessory to protect the protective coating on the boiler internals.
3CaCO3 + 2Na3PO4 (sodium triphosphate) Ca3(PO4)2 (calcium triphosphate)

+2Na2CO3
RAW WATER AND CIRCULATING WATER SYSTEM:-
RAW WATER:-The total water requirements for running of the units are supplied by
the intake pump house in the raw water form. The raw water is taken from Sirhind canal
near the plant area and stored in the storage ponds. There are separate ponds for units.
The ponds act as a water reservoirs since the canal runs dry once in a month for 7 days.
Normal season has a normal supply of water. In order to destroy algae and bacteria in
water chlorination is done intermittently at the suction of intake pumps. In the intake
pump house which is common for stage-1,2 there are six number of pumps, one pump
for each unit and two acts as standby.
Particulars of pumps:-
Capacity of each pump 1200 m3/hr.
Total head 8 MWC
Suction pressure 0.3-0.46 kg/cm2
Motor 415 Volts, 45 kW
Page | 34
CIRCULATING WATER:-
There are two C.W. pump houses, one for unit-1,2 (stage-1) and other for unit-3,4
(stage-2). In each C.W. pump house there are five number of pumps for circulating
water, two pumps for each unit having 50% capacity and pump is stand by for both
units. The particulars of C.W. pumps for unit 1,2 are:-
Manufacturer : M/s Johnson Pumps Ltd. Calcutta
Type of pump :Wet pit, mixed flow, vertical directly coupled with an
electrical motor drive.
Pump Bearing lubrication : Forced fresh water from external source.
Design capacity : 8600 m3/hr.
Motor : 800 kW, 6.6 kV, 50Hz, AC Induction motor of BHEL,
Haridwar.
Page | 35
BOILERS:
a) Type = Natural circulation, water tube, single drum with radiant reheat semi
outdoor unit.
b) Make = Bharat Heavy Electricals Limited
Stage I Stage II
c) Capacity 690 T / hour 810 T/hour
d) Steam Pressure 155 Kg/cm2 155 Kg/cm2
e) Steam Temperature 540 C 540 C
LOW TEMPERATURE SUPER HEATER
The LTSH section is of continuous loops, plain tubular, drainable, horizontal, in

line spaced type, with steam flow upwards and gas flow downwards arrangement. This
section is in two blocks and located above the economizer section, in the back pass of
the unit. This convective spaced bearing surface has 120 assemblies, 4 elements per
assemblies. The out let section of LTSH alone is arranged vertically.
Page | 36
RADIANT PLATEN SUPER HEATER
The radiant platen super heater is of the continuous loop, plain, tubular, non-
drainable, vertical inline tangent tube type, arrangement for parallel flow. The platen
super heater section assemblies are widely spaced, and located in the radiant zone at the
furnace outlet section. The radiant platen heating surface has 29 assemblies, 7 elements
per assembly.
FINAL (FINISH PENDENT) SUPER HEATER (FSH)
Final pendent super heater (FSH) section, is of spaced type continuous loop, plain
tubular, non-drainable, vertical in line spaced type, arranged for parallel flow. This FSH
is located in the horizontal pass, after re-heater section. The convective final super
heater has 89 assemblies-2 elements per assembly.
RE-HEATER SYSTEM
The re-heater section is single stage, spaced type, continuous loop and plain
tubular, non-drainable, vertical inline spaced type, and arranged for parallel flow. The
re-heater front pendent and rear pendent section is located in the horizontal pass, in
between the radiant platen super heater and final super heater section. This convective
re-heater section has 59 assemblies-6 elements per assembly. The approximately total
convective heating surface is 3100 m. The entire re-heater section is suspended from
the roof structural steel sections.
WATER WALL SYSTEM
The water wall system comprises of front wall, rear wall, side walls all of fusion-
welded construction.
RISER PIPES
From the outlet headers of the water wall system, the steam water mixture is taken to
the steam drum through 118 numbers pipes rolled up-risers.
WATER WALL/FURNACE DESIGN PRESSURS
The complete furnace wall, and the other steam cooled walls (in the second pass),
are strengthen by providing buck stays and tie bars system to with stand pressure/forces
SUPPORTS/SUSPENSION
The complete circulation system is suspended from boiler roof structure & is
arranged for free expansion downwards.
Page | 37
FURNACE
The furnace hopper outlet section is provided with an opening of approx.1100

mm depth for full width of the furnace. On each sidewall, in the furnace hopper area,
one water-cooled access door (oval in shape) is provided. These openings are provided
for taking maintenance cradle parts/ scaffolding sections etc. inside the furnace during
maintenance of the furnace.
SPECIAL FITTING AND VALVES
Access doors, feed water valves, gauge glasses and safety valves etc. are included
under this heading. The access doors are installed at:
FEED REGULATION STATION
The location of this station is at AB elevation and feed water supply to the boiler
is regulating through this station. During initial period of starting the unit, feed is
regulated through 30% line because the requirement of water is small during this period.
Later on during normal operation, any of the 100% line on left or right is charged.
Other is standby all the valves (isolating and regulating) are operatable from UCB.
Before taking the above lines into circuit, the whole piping has to be thoroughly vented
to avoid possibility of air lock in the boiler system.
Page | 38
SUPERHEATER AND RE-HEATER ATTEMPERATION HEADER
Attemperation or de-super heating is one of the methods for controlling the steam
temperature. Correct and un-fluctuating temperature of the steam is of paramount
importance. While excessive temperature is injurious to boiler/turbine metals, the low
temperature below certain limit is unacceptable at turbine. Fluctuation in main steam
temperature has still more server effects on turbine.
Both the attemperation header station is located at AB elevation. These headers

are connected to the feed line (going to the boiler) before the feed regulating station i.e.
discharging line of BFP. There is only one injection in SH circuit i.e. between LTSH and
platen super heater for controlling RH steam temperature, there is one injection in CRH
line. The arrangement of SH sprays and RH spray.
CONDENSER
A condenser where the exhaust steam from the turbine is condensed, operates at a
pressure lower than atmosphere. There are two objects of using a condenser in a steam
plant.
There are two objects of using a condenser in a steam plant:-

To reduce the turbine exhaust pressure so as to increase the specific output of turbine. If
the CW cooling water temperature in a condenser is low enough. It creates a back
pressure (vacuum) for the turbine. This pressure is equal to the saturation pressure
corresponding to the condensing steam temperature. Which is a function of cooling
water temperature. It is known that the enthalpy drop or turbine work per unit pressure
drop is much greater at the low pressure end than at the high pressure end of a turbine.
A condenser by lowering the back pressure say 1.013 to 0.074 bar, thus increases the
plant efficiency and reduces the steam flow for a given output. The lower the pressure,
the greater the output and efficiency. It is important to use lowest possible cooling water
temperature.
This reduces the temperature rise of cooling water in the condenser tubes to 5-8C so
that the tube outer surface temperature remains low and consequently, the condensing
steam temperature is low and vacuum is high.
To recover high quality feed water in the form of condenser and feed it back to the
steam generator without any further treatment.
As a result only the make up water to replenish the water losses in the cyclic plant needs
be treated.
Page | 39
DIRECT CONTACT CONDENSERS:-
Spray condenser
Barometric condenser
Jet condenser
In the spray condenser, the cooling water is sprayed into the steam. Steam by mixing
directly with cold water gets condensed. The exhaust steam from the turbine at state 2
mixes with cooling water at state 5 to produce saturated water at state 3, which is
pumped to state 4.
In barometric condenser, the cooling water is made to fall in a series of baffles to

expose large surface area for the steam fed from below to come in direct contact. The
steam condenses and falls in a tail pipe to the hot well below. By virtue of its static
head, the tail pipe compresses the mixture to atmospheric pressure.
In a jet condenser, the height of the tail pipe is reduced by replacing it with a diffuser.
The diffuser helps raising the pressure in a short distance than a tail pipe.
SURFACE CONDENSERS:-Surface condenser is another type of condenser used in

power plants. In GURU NANAK DEV THERMAL PLANT surface condensers are
used. These are essentially shell and tube heat exchangers. For the convenience of
cleaning and maintenance cooling water flows through the tubes and steam condenses
outside the tubes. In our plant surface condenses two passes of water boxes on each
side. The hot well acts as a reservoir of the condensate. The condenser plays a vital role.
In our plant two surface condensers are used in one plants unit. There are 6800 tubes in
one condenser.
CONDENSER
Page | 40
CONDENSATE CYCLE:- Steam after working in the three casings of the turbine i.e.
H.P., M.P. and L.P. casing is considered in two surface condensers in each unit installed
just below the L.P. turbines exhaust hood. The condenser so to call hot well from where
it is pumped up to deaerator by condensate extraction pumps through different heating
stages. The different heating stages through which the condensate flows and gets heated
up gradually before finally reaching the deaerator (feed water tank) are as below:-
HEATING STAGE TEMP. RISE AT FULL LOAD
Main steam jet air ejector 43-48C
LPH-1 and LPH-2 48-73C
Chimney steam condenser 73-80C
Gland steam condenser 73-80C
LPH-3 80-97C
LPH-4 97-121C
LPH-5 121-152C
Deaerator 152-158C
The temperature rise of the condensate after passing through above heating stages is
from 45C at hot well to 145C at the deaerator (feed water tank). The feed water tank
acts as a feed water storage vessel and deaerator functions to remove dissolved oxygen
in the feed water.
CONDENSER:- The function of the surface condenser is to condense the steam

exhausted from the L.P. casing and to create vacuum in order to increase the heat drop.
Capacity of each hot well is 6200 liters and the temperature of condensate in the hot
well is about 40-45C.
PARTICULARS OF CONDENSATE:-
EXTRACTION PUMP:-
Number of pumps: 3 for each unit with 50% capacity each, one stand by.
Number of stages: 6
Discharge pressure: 20.5-24.5 kg/cm
Suction pressure: -0.8 to 0.9 kg/cm
Page | 41
Steam Jet Air Ejector:-
The main function of steam jet air ejector is to maintain the vacuum in the steam
condenser by ejecting the air and non-condensate gases. The steam from pressure
reducing station is supplied to steam jet air ejector. This steam when passed through the
nozzles in a venturi develops pressure drop, which causes the air and non considerable
gases to rush from the condenser, thus maintaining the required vacuum in the
condenser. After that heat of this steam is utilized in heating up the main condensate
flowing through in the steam jet air ejector. The steam jet air ejector is built up in the
condenser.
LOW PRESSURE HEATERS:-
There are five numbers of L.P. heaters through which the main condensate flows and
gets heated up gradually in each stage of heaters before finally going to the deaerator.
The L.P. heaters 1 and 2 are in two parts and placed in the exhaust hood of
condenser i.e. exhaust hood of L.P. turbine and are connected in series. L.P.H.-3, L.P.H.-
4 and L.P.H.-5 are placed in chimney steam condenser and gland steam condenser in the
condensate flow circuit. The charging steam to these heaters is given from the steam
extractions taken from the L.P. & M.P. cylinders of the turbine. Steam extraction to
L.P.H.-1 is taken from L.P. casing in two parallel flows, same in L.P.H.-2. Steam to
L.P.H.-3 is also taken from L.P. casing. Where as steam to L.P.H.-4 and L.P.H.-5 is
taken from M.P. casing.
The main condensate gets heated up by about 100C after passing through these heating
stages. The condensate of heating steam in these L.P. heaters is known as drip.
DEAERATOR:-
It is a cylindrical vessel placed at 36 meters level, with the purpose to remove the
dissolved oxygen air and other gases from the feed water i.e. called deaerator of feed
water. In order to accomplish high degree of efficient deaeration, feed water is sprayed
through the sprayer stage and then through the stack of trays.
Trays and spray chambers are in one enclosure called deaerator. Steam supplied at
the 6 atm. enters through the bottom of this enclosure and rises above into the spray
chamber through the stack of trays.
The feed water after deaerator is collected in a feed water tank attached with the
deaerator. A part of 6 atm. steam is also used for cushioning purposes and heating in
feed water tank. This tank also acts as a storage tank for feed water and to the suction of
boiler feed pump is taken from this feed water tank.
Page | 42
SUPERHEATERS:
This is one of the most important accessories of a boiler. Superheated steam effects
improvements and economy in the following ways: -
By reducing the steam consumption of the steam engine or steam turbine. By producing
more work per lt. Steam.
By reducing the condensation losses in steam mains and in engine cylinder.
By eliminating erosion of steam turbine blades.
By increasing the capacity of the plant.
By reducing the friction of the steam in the steam parts, while entering and leaving the
cylinder.
Steam consumption of turbine is reduced about one percent for each 10o f of superheat.
This saving is partly due to increase in volume of steam but mostly because absence of
moisture decreases superheated steam in engines is about 1.5 to 2% for each 10o of
superheat. This is due to greater volume of superheated steam and therefore to the less
weight of steam required to fill the cylinder up to the point of cut off and due to
decrease in cylinder condensation. The saving mentioned above drops off slightly as the
amount of superheat is increased.
REHEATER SYSTEM
The reheater section is a single stage spaced type continuous loop, plain tubular, non-
drainable, vertical inline spaced type and arranged for parallel flow. The reheater-front
pendant and rear pendant section is located in the horizontal pass, in between the radiant
platen superheater and final superheater section. This convection reheater and final
superheater section has 59 assemblies, 6 elements per assembly. The approximately
total convective heating surface area is 2910 m 2. The entire reheater section is
suspended from the roof structured steel sections.
FURNACE
Furnace is the primary part of boiler where the chemical energy available in the
fuel is converted to thermal energy by combustion. Furnace is designed for efficient and
complete combustion. Major factors inside the furnace, temperature inside the furnace,
and turbulence, which causes rapid mixing between fuel and air.
Page | 43
Bharat Heavy Electricals limited has developed the modern water-cooled furnace.
At the present time water cooled furnaces are supplied on every type and size of boiler.
Water cooled furnace has the following advantages:
In furnace not only combustion but also heat transfer is taking place simultaneously.
The maintenance work involved in replacing the fire bricks (which is otherwise
necessary) is practically eliminated.
Due to heat transfer in the furnace the fuel gas leaving the furnace is reduced to the
acceptable level to the superheating surface.
Higher heat lading in the furnace is possible as heat transfer is simultaneously removing
heat. And have total economy in surfacing.
The furnace hopper outlet section is provided with an opening of approx 1100 mm
depth, for the fuel width of the furnace. On each side wall, in the furnace hopper area,
one water cooled access door (oval in shape of size 406*457 mm is provided. These
openings are provided for taking maintenance of the furnace.
WATER WALLS: This means that the walls are water cooled. The water tubes are
embedded in the walls. The heat absorbed by the walls is conducted to water tubes,
from which it is absorbed by the water. These tubes are backed by refractory section.
The tubes protect the walls from erosion.
The major parts of a furnace are listed below:
Water Tubes
Furnace Corners
Refractory Walls
Wind Box
Dampers
Flame Sensors
Oil Guns
Soot Blowers
These parts are described below:
WATER TUBES: These are the very long pipes made of Alloy Steel . The inner
diameter is 63.5mm. There are total 712 tubes. The water is made to flow in these pipes.
FURNACE CORNERS: There are four furnace corners. Each corner consists of six
carrier pipes ends, coming from Bowl Mills, four secondary air openings, and three oil
guns. All the openings are tilted to 24 deg below or above the horizontal.
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WIND BOX AND DAMPERS: there are twowindboxes one is installed at right sideand
other is on left side. The height of each wind box is 7m and width is 1m.It is used to
store the secondary air and dampers are provided to regulate the supply of secondary air.
There are four dampers on each corner.
FLAME SENSORS: these are used to check wether the coal is burning fully or not. It is
checked by analysing the flame producing in furnace.
OIL GUNS: these are used to fire the coal at start up of the furnace. The LDO(Light
Diesel Oil) and HFO(Heavy Furnace Oil) are used to light up the furnace.
ADVANTAGES OF WATER COOLED FURNACE:
Water cooled furnace has the following advantages:
In furnace not only combustion but also heat transfer is taking place simultaneously.
The maintenance work involved in replacing the firebricks (which is otherwise

necessary) is practically eliminated.
Due to heat transfer in the furnace the fuel gas leaving the furnace is reduced to the
acceptable level to the superheating surface.
Higher heat lading in the furnace is possible as heat transfer is simultaneously removing
heat. And have total economy in surfacing.
The furnace hopper outlet section is provided with an opening of approx.

1100-mm depth, for the fuel width of the furnace. On each side wall, in the furnace
hopper area, one water cooled access door (oval in shape of size 406*457 mm is
provided. These openings are provided for taking maintenance of the furnace.
FANS
Three types of fan:-
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1. Primary air fan (PA FAN)
2. Forced draft fan (FD FAN)
3. Induced draft fan (ID FAN)
1. PRIMARY AIR FAN

P.A. fan is a part of F.D. fan system. It also supply air in the furnace for combustion. Air
supplied by P.A. fan and F.D. fan combine together to make total air flow in the furnace.
PA FAN
Air supplied by P.A. fan is used to dry and transport the pulverized coal from coal mill
to furnace and is referred to as primary air.
In this type of fans, the medium handled enters the impeller axially and after passing
through the impeller leaves radially. A large part of the energy transferred to the medium
is converted into pressure energy. Constant speed motors generally drive these fans. The
output of the fan is usually controlled by inlet dampers or inlet guide vanes or by
varying the speed of the fan by suitable speed control device.
TECHNICAL SPECIFICATIONS:
No. of fans : 2
Type : NDV 22 TIEF
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WhereNDV Radial singlesuction simply supported 22 nominal tip dia of
impeller in decimeter
TIEF Type of impeller.
Medium handled : Air
Location : Ground
Orientation : Inlet 450 inclined, outlet
bottom horizontal
FAN DESIGN RATING
Capacity : 70 m3/ sec
Total head developed : 1220 mm WC
Temp of medium : 500C
Specific weight of medium : 1.044 Kg/m3
Speed : 1480 rpm
FAN RESERVE
Flow : 84.7%
Pressure : 51.5%
FAN DRIVE COUPLING
Make : VOITH
Type : Hydraulic
DRIVE MOTOR
Male : BHEL
Frame size : M C 75288 H4 ATH
Type : square cage induction
Rating : 1259 KW
Speed : 1480 rpm
Fan Weight : 18.9 tons

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LUBRICATION
Fan : FLOS ISO VG 68
Motor : Servo gem 3
2. FORCED DRAFT FAN

To supply air at required pressure to furnace for proper combustion.
To control the quantity of air in the furnace.
In the axial reaction fans (Type A P), the major part of ( about 80%) energy
transferred is converted into static pressure in the impeller itself. The rest of the energy
is converted into static pressure in the diffuser. These fans are generally driven at
constant pace. The flow is controlled by varying the angle of incidence of impeller
blades. It therefore becomes possible by this process to achieve high efficiencies even
during part load operation.
TECHNICAL SPECIFICATIONS:
Type : A.P. I-18/11
Where A.P.-1.Single stage axial profile bladed fan.
18- Nominal tip dia of impeller in decimeter
11- Nominal hub dia of impeller in decimeter.
No of fans : 2 per boiler and both running
Medium handled : Air
Location : Ground
Orientation : inlet vertical outlet horizontal
FAN DESIGN RATING
Capacity : 110m3/s
Total Head developed : 520 mm WC
Temperature of medium : 500C
Specific Weight medium : 1.044 Kg/m3
Speed : 1480rpm
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FAN RESERVE
Flow : 43%
Pressure : 49%
FAN DRIVE COUPLING
Make : Unique transmission
Type : RIG/FLEX COUPLING
DRIVE MOTOR
Make : BHEL
Frame Size : MC 74224 H4 A8H
Type : Square cage induction
Rating : 750 KW
Speed : 1480 rpm
Fan weight : 8.4 tons
LUBRICATION
Fan : FLOS ISO VG 68
Type of fan regulation : Blade pitch control
BEARING
Fan fixed bearing : 7230 BUA
Fan free bearing : NU 230 C3
RECOMMENDED BEARING RADIAL CLEARANCES
Before mounting : 0.115 mm to 0.150mm
After mounting : 0.065 mm to 0.100mm
OPERATION OF FD FAN : -
One FD fan should be running for starting one FD fan and two ID fans should be
running for starting second FD fan.
Discharge damper should be in closed condition.
Control station should be on Manual Mode.
Regulating vane or controlled actuator should be in minimum position.
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Lubricant oil system O.K. from fan pane. This includes:
Control oil pressure after pumps should be adequate i.e. 8 Kg/cm2.
NDE/DE bearing temperature of fan normal 950 C.
NDE/DE bearing temperature of motor normal 750 C.
Control supply on.
Local push button reset.
Note:Control vane of FD fan will not operate till control oil pressure is not adequate i.e.
it should be 8 kg/cm2.
3. INDUCED DRAFT FAN

To remove flue gases from the furnace and throw it in a atmosphere through chimney.
To maintain ive pressure (draft) in the furnace i.e. 5 mm WC to 7 mm WC.
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The type an fan operates according to the impulse principle. The major part of the
energy transferred to the gas appears as the velocity energy after the impeller. This
velocity energy is converted into pressure energy by the diffuser. Usually, the an fans
are driven at constant speed and the flow is controlled by changing the direction of gas
entering to impeller blades. For this purpose, adjustable guide vanes are used before the
impeller.
ID FAN
TECHNICAL SPECIFICATIONS: -
Type : AN 25e6
where
AN axial non-profiled bladed fan 25- Nominal tip dia of impeller in decimeter
e6 type of diffuser
No of fans :3
Medium Handled : Flue gas
Location : Ground
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Orientation : Inlet vertical
: Outlet horizontal
FAN DESIGN RATING
Capacity : 230 m3/s
Total head developed : 350 mm WC
Temperature of medium : 1500 C
Specific weight medium : 0.813 Kg/m3
Speed : 980rpm
FAN RESERVE
Flow : 35.7%
Pressure : 38.3 %
FAN DRIVE COUPLING
13.Make : BHEL
14.Type : Flexible
DRIVE MOTOR
15.Make : BHEL
16.Frame size : AC 14256 H6 A8H
17.Type : Square cage induction
18.Rating : 1300KW
19.Speed : 980rpm
20.Fan weight : 21.7 tons
LUBRICATION
21.Fan :Grease Servo Gem EP2
22.Motor :FOLS Mobile DTE of IOC
23.Type of fan regulation :Inlet guide vane
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BEARINGS
24.Fan fixed bearing : Anti friction 22328 C3
25.Fan expansion bearing : Anti friction 22232 C3
STARTING PERMISSIVES: -
1.Suction and discharge damper in closed position.
2.Central actuator or regulating vane in minimum position.
3.Central station on manual position.
4.Stack path available.
5.Lubricant oil system O.K. (from local fan panel ). For this condition to be O.K.
following is required: -
Fan bearing (DE and NDE) temperature normal 950 C.
Motor bearing (DE and NDE) temperature normal 750 C.
Lubricant oil pressure O.K. 1.5 Kg/cm2.
Control supply of fan panel should be on.
6.Local push button reset.
ECONOMIZER
An economizer is a heat exchanger, which raises the temperature of the feed water
leaving the H.P. Heaters to about the saturation temperature corresponding to the boiler
pressure. The hot flue gases exiting the super-heater at a temperature varying from 370
to 540 C lose their heat to the water, thus making the water hot, thus recovering the heat
from the flue gases leaving the boiler.
The feed water is supplied to the economizer inlet heater via the feed stop and check
valves. The feed water flow is upwards that is in counter flow to the hot flue gases.
Most efficient heat transfer is accomplished here. Any difficulty of steam generation is
eliminated by the upward water flow. From the outlet header the water is sent to drum.
The economizer with a heating surface of 4930M 2 is made of seamless steel tubular
loops.
SUPER-HEATER
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The super-heater is a heat exchanger in which heat is transferred to the saturated steam
to increase its temperature. It raises overall cycle efficiency. The super heater is
composed of four sections a pendent spaced section, a platen section, a rear section, a
rear horizontal section and the steam cooled wall and roof sections. The steam
superheated has a total heating surface of 3782 seq. meter.
The platen section is located directly above the furnace in front the furnaces arch. It
absorbs the heat mainly by radiation.
The pendent section is located behind the screen tubes. The predominant mode of heat
transfer is convection.
The horizontal section of the super heater is located in the rear vertical gas pass above
the economizer. This is the primary super-heater of the convective ,counterflow type.
The steam cooled wall suctions form the front and rear walls and roof of the vertical gas
pass.
BOILER EFFICIENCY
Boiler efficiency is defined as the heat added to the working fluid expressed as a
percentage of heat in fuel being burnt. The theoretical limit to boiler efficiency is 100%
unlike in case of turbo generator, whose efficiency is limited by cycle efficiency. Boiler
heat only because it would be extremely difficult and not a paying proposition to
recover it all. Thus maximum boiler efficiency is thought in terms of an optimum
efficiency, which depends on fuel being burnt and the fact that waste products of
combustion take away heat with them.
Boiler efficiency depends solely on the boilers ability to burn the fuel and transfer the
resulting heat to water and steam. The pressure and steam, although profoundly altering
cycle efficiency and turbine efficiency, have no material effect on boiler efficiency.
The boiler efficiency will depend to great extent on the skill of their designing but there
is no fundamental reason for any difference between a high pressure boiler and a low
pressure boiler or between a reheat and non-reheat. Generally speaking a large boiler
would be expected to be more efficient than small boiler, and as increase in pressure and
temperature have developed; it has been accompanied by an increase in size. So there
might be tendency to think that higher efficiency of most modern boiler is due to
advance steam cycle condition where as it is infect attributable to increase in physical
size and improvement in the art of boiler making in general fuel burning in particular.
A boiler, however must be able to meet the following design requirements :-
Page | 54
1. Be able to produce steam at required temperature and pressure over an
appreciable range load take in feed at a temperature which varies with turbine
load.
2. Be capable of following changes in demand for steam without excessive pressure
swing.
3. Be reliable with high availability
METHOD OF EFFICIENCY CALCULATION :-
I. DIRECT METHOD
II. INDIRECT OR LOSSES METHOD
THE DIRECT METHOD :- This method is straight forward and consist measuring in
heat supplied to the boiler and heat added to the steam in the boiler in a given time.
BOILER LOSSES :-
Dry flue gas loss.

Wet flue gas loss (loss due to moisture in fuel and due to moisture formed by
combustion of hydrogen in fuel).
Moisture in combustion air loss.
Unburnt carbon loss-carbon in ash loss.
Unburnt gas loss-due to incomplete combustion of carbon.
Radiation and unaccount losses.
DRY FLUE GAS LOSS :-
This is the heat lost in the dry component of the gases, as these are discharged
from the chimney at a temperature considerably higher than atmospheric temperature.
Carbon and sulphur are the constituents in fuel that produces dry flue gas. Let us ignore
S for the moment. Now C can burn to form CO2 or CO so the only gases in the dry flue
gas will be CO2, CO, O2 and N2 the last two coming from combustion air.
The dry flue gas loss depends on two factors
Excess air
Air heater gas outlet temperature
Both these factors are to be considered extent under the control of the operator.
Excess air is the quantity of the air required to be fed over the theoretical amount of air
required for complete combustion. This is required because with the theoretical air it is
not possible to have all the O2 molecules come in contact with fuel particle at the right
time resulting in poor combustion. If too little excess air supplied, fuel is not completely
burnt, if too much quantity of air is supplied, the being carried up in the stack will be
Page | 55
greater than the normal quantities. N2 which constitutes about 79% of the air merely a
passenger, it requires fan power and carries away heat. The changes in the dry flue gas
loss with excess air.
Air infiltration should be controlled to limit this loss. Air in leakage apart from
lowering boiler efficiency also affects performance of ESPs and increases ID fan
loading.
Air heater gas outlet temp.the air heater gas outlet temp.should be lowest from the
point of overall efficiency, on the other hand this temp. is required to be high on account
of corrosion.
For Indian outlaws having low percentage of sculpture. The specified all gas
outlet temperature is of the order of 130C. High heater air gas temperature reduces
boiler efficiency drastically.
WET FLUE GAS LOSS
Due to moisture in fuel :- Moisture that enters the combustion as part of fuel cause a
heat loss because it must be heated from its initial temperature to leave boiler
temperature to boiling point, then evaporated and finally super to leave boiler at the
same temperature as flue gases. This loss is about 0.5 to 1%.
Heatless per kg moisture in fuel
= Cpw(100 - 1) + LII + Cps (t - 100)
= 4.2 (100 - 1) + 225 + 2 (T - 100)
= (2477 + 2T - 4.2t) kj/kg
= m (2477 + 2T - 2.2t), M being moisture per kg fuel
Where Cpw = specific heat of water = 4.2 kj/kg I, II is latent heat of vaporization
at atmospheric pressure = -2257 kj/kg
Cps = Mean specific heat of superheated steam at atmospheric pressure = -

kj/kg
A part from this loss moisture also affects milling plants and consequently boiler
efficiency.
Causes of high carbon in ash are :-
Coarse grinding
Mal adjustment of flame
Page | 56
Unequal loading of different mills
Incorrect P.A. air temperature
Low temperature causes condensation and high temperature causes caking, both
resulting in blocking of coal pipes.
The causes of coarse grinding for a medium speed section mill of lopulco type
include :-
Mill in need of adjustment e.g. rolls too far off the table, spring tension
insufficient etc.
Exhauster speed too high relative to coal feed.
Weal fuel/air mixture i.e. high P.A.
Excessive air in leakage to mill.
Separator speed too low.
Causes of low carbon in ash (Over grinding)
Exhauster speed too low.
Mill in need of adjustment e.g. rolls too low, spring tension too high.
Mill table dam ring too high.
Rich fuel/air mixture i.e. less P.A.
Separator speed too high.
RADIATION AND UNACCOUNT LOSSES :-
Unaccounted losses include heat carried away ash, heat loss in bottom hopper
seal water, loss from boiler casing to surrounding, losses due to unburnt volatile matter,
loss due to combination of carbon and water vapour. These losses account for about 1%
loss and are calculated by graphical methods and alignment charts.
Radiation loss depends on the effectiveness of the boiler casing insulation. High
quality insulation couple with water-cooled furnaces keeps the value low. Also the loss
is reduced by taking forced draught air from inside the boiler house. The radiation heat
is recalculated to the boiler via the warmer air supplied to the forced draught fan
intakes, so reducing the loss appreciably. This is independent of variations in excess air.
As a percentage, this loss varies with the size of unit, because surface area of casing is
proportionately lower for a large unit than for a small unit.
Moisture in combustion
H2 + O H2O
Moisture in air loss

Page | 57
Let Wm is moisture in air/kg fuel
Loss = Wm+ 2(T - t) kj/kg fuel
This is because moisture in air is already in vapour form, so no sensible heat is

involved. This is usually very small and is not normally calculated.
From this, so no sensible heat or latent heat is involved. This is usually small and
normally calculated.
OTHER PARAMETERS AFFECTING BOILER EFFICIENCY :-

Control Of Low Down And Make Up :-
Boiler blow down and corresponding makeup is also factor contributing to
efficiency fine drum level control and strict boiler water chemical control reduces the
makeup requirement.
In fact blow down causes two fold loss :(a) by way of water loss and subsequent
make up (b) by way of water blown and subsequent heating of make up water.
OPTIMIZATION OF OIL CONSUMPTION :-
P.F. boiler consumes oil under different operating condition. It makes little
difference in heat consumption if oil used as substance to coal, but the cost of
generation is high in case of using oil than the coal. As such dependence of oil should
be fob individual boiler. This is very vital point in reducing cost of generation.
ENERGY ANALYSIS:-
One of the main applications of engineering thermodynamics is the study of

process effectiveness. Traditional techniques are of two types:-
Use of an energy balance on the system usually to determine unaccounted for heat
between system and environment.
Calculation of criterion performance relevant to the system under consideration.
The traditional methods of process analysis are based in the main on the first law
of thermodynamics. The kind law is brought into formation of such criteria of
performance as isentropic efficiencies even though it governs the limits of convertibility
between different forms of energy and determines the relative grades or quality of this
energy form. Hence it is the failure to consider of change energy quality during a
process, which makes traditional thermodynamic analysis methods unsatisfactory.
Page | 58
THE ENERGY METHODS:-
The energy method is an alternative relatively new technique based on the

concept of energy loosely defined as a universal measure of the work potential or
quality of different forms of energy in relation to an environment. An energy balance
application to a process or a whole plant tells us much of the usable work potential or
energy supplied as the input to the system under consideration has been consumed by
the process. The loss of energy or irreversibility provides a generally application
quantities measure of the process inefficiency. Analyzing a multi component plant
indicates the total plants irreversibility distribution among the plant component
pinpointing those contributing most to overall plant inefficiency. Unlike the traditional
criteria of performance the concept of irreversibility firmly based on the two laws of
thermodynamics.The energy balance for a control region from which the irreversibility
rate of leady flow process can be calculated.
It can be derived by combing the steady flow energy equation with the expression
for the entropy production rate. Although the second law is not used explicitly in the
energy method its application to process analysis demonstrates the practical to process
analysis demonstrates the practical implications of the second law. Thus studying
different forms of irreversibility and their effect plant performance gives a better more
useful understanding of the second law than studying its statements and corollaries
quality of the disordered energy forms characterized by entropy is depends both on the
form of energy and on the parameters of the energy. one of the main uses both this
concept is an energy balance in the analysis of thermal system. the energy balance is
similar to an energy balance had the fundamental difference that while balance is a
statement of the law of conversations of energy , but the law of degradation of energy
balance may be looked upon as a statement of the law of degradation of irretrievable
loss of energy due to all real processes being irreversible.
GENERATOR DESCRIPTION
The generator stator is a gas tight construction, supporting and enclosing the
stator ruction, supporting and enclosing the stator winding, core and hydrogen coolers.
The cooling medium, hydrogen, is contained within the frame, and circulated by fans
mounted at either end of the rotor. The generator is driven by a directly coupled steam
turbine at a speed of 3000 rpm.
Page | 59
Provision is made for regulating the cooling water in order to maintain a constant
temperature of the order to maintain a constant temperature of the coolant (Hydrogen)
as measured on the fan suction side, which in turn controls the temperature of windings,
core etc. as per the load.
Stator Frame
The stator frame is casing of welded plate construction. The function of stator
frame is to contain and support the stator core, windings, hydrogen coolers (in a
horizontal configuration), and also to provide paths for distributing the cooling
hydrogen through the generator, internal section plates provide stiffness to support the
core, decrease vibration and impact necessary mechanical, strength to withstand the gas
pressure encountered even under extreme operating conditions. Wedge shaped steel
guide bars are welded on the beams in the stator to support the stator core. The stator
frame is supported the foundation through footing welded to the sides of the shell. The
end shield are made of manganese steel casting, are bolted to the inside of the shields.
The end shields, coolers, inspection windows etc., are carefully sealed to prevent
any leakage of hydrogen from the generator and the entire generator is leak-proof.
Owing to the explosive nature of the mixture of hydrogen and air, the frames are
designed to withstand any incidental exposing and over pressure that may develop.
Stator Core
The stator core is built up of segmental, annealed laminations of hot or cold rolled
high quality, silicon steel to give minimum electrical loss. The laminations are insulated
with a thermosetting varnish which retains its properties upto a temperature well above
the normal operating range. These laminations are assembled in an interleaved manner
on the machined guide bars. They are separated into packets of approx. 50 mm thick by
the radial ventilating ducts. The punching is stamped from steel sheets of 0.5 mm
Page | 60
thickness. In addition to open slots for the windings in the inner periphery, dovetail slots
are punched at the outer edge of the lamination for assembly and locking of the
segments on the guide bars. The assembled laminations are clamped into a stiff
cylindrical core by pressure applied through non-magnetic steel end clamping plates
with pressing fingers. Use of non-magnetic steel reduces considerably the heating of the
end iron. The guide bars are at the outer diameter of the magnetic core and, as such, are
not insulated from the core.
In order to reduce end heating from end leakage flux, and it is assess, end packets
of lamination are stepped back to increase the gap between the laminations and rotor.
Stator Winding
The stator winding is a double layer, lap wound, six phases, and short pitch type.
The top and bottom are brazed and insulated at either end to from a turn. The phases
are connected to form a double star winding. The end winding formed with involutes
shaped bar ends, is inclined towards the machine exist by 20, thus forming a basket
winding with total included conical angle of 40. This minimizes the stray load losses in
the stator end zone.
Hydrogen Coolers
The hydrogen cooler elements assembly consists of several rows of admiralty brass
cooling of several rows of admiralty brass cooling water tribes, with copper fins. The
copper fins assembly is tinned to increase thermal conductivity and bright tube fin
clearances. Such individual tube assemblies are then fitted between two correspondingly
perforated soiled end plants and the tube ends expanded. The assembly is made rigid by
stiffening plants suitably located. The heat absorbed by gas in cooling the machine is
removed while passing over these finned tubes of the hydrogen coolers.
The coolers are mounted within the stator casing co-axially in the outer frame. In
the outer frame, 3 pockets, 2 on either side diametrically opposite in the horizontal
Page | 61
plane and the third on top in the stator casing along the full lengths have been provided
and each pocket accommodates two cooler elements, mounted back to back.
Rotor
The turbo-generator rotor is forged from a single piece of special chromium,

nickel and molybdenum alloy steel carefully heat treated to obtain the required
mechanical and magnetic properties. The forging undergoes a series of stringent quality
control tests, before it is accepted for further processing. Longitudinal slots are then
milled radially in by rotor body and winding. The field coils are held in the slots against
centrifugal force by wedges, both magnetic and non-magnetic types being used to
ensure a better wave from flux distribution. These wedges are individually fitted and
driven into dovetail openings machined in the rotor.
GENERATOR OPERATION
Final inspection of Generator before starting for the first time.
One of the most important events in the life cycle of a turbo generator is the initial
start up. During this period, each component of the unit is checked and tested for proper
installation and operation as follows :-
1. Check the connection of the stator terminals with the bus bars.
2. Check that the voltage on the generator name plate corresponds to the incoming
voltage.
3. The stator coil resistance temperature detects should be checked to made sure
they are indicating properly.
4. The shaft sealing system must be put into operation.
5. The rotor should be rotated slowly before the generator is placed in service, to
determine whether rubbing occults are any point. The machine should initially
bold up speed slowly to check for mechanical balance.
6. The slip rings should be carefully inspectedfor any scratches or rough spots. The
fixing and adjustment of brushes is done.
Page | 62
7. Check the insulation resistance of the winding.
8. Thermometers installed in the bearings and signalized equipment should be tested
for proper operation.
SHUTTING DOWN
1. Cut off the load gradually from the machine and pen generator circuit breaker.
2. The switch for de-excitation provided in the automatic voltage regulation is
operated.
3. The water to the hydrogen coolers in shut off at same time the steam to the
turbine is cut off.
When shutting down the generator all excitation must beer moved when the
generator is down to 20-25% of read speed. If this is not done, the field winding
temperature will rise due to inadequate ventilation since the cooling gas
circulated is proportional of the speed.
The seal oil system should, however, be kept in operation as long as the gas is
under pressure inside the machine
TURBINE
Turbine is a prime mover for the Generator in the power plant. In steam turbine, the
potential energy of steam is transformed into kinetic energy and later in its turn is
transformed into the mechanical energy of the rotation of the turbine shaft. The common
types of turbines are:-
Page | 63
IMPULSE TURBINE:- In this type of turbine, steam expands in the
nozzles and its pressure does not alter as it moves over the blades.
REACTION TURBINE:- In this type of turbine, the steam expands

continuously as it passes over the blades and thus there is a gradual fall in
pressure during expansion.
IMPULSE TURBINE REACTION TURBINE
Different types of steam turbines are used in Thermal Power Plant but the ones which
are used at G.N.D.T.P. are categorized as follows:-
Sr. No. Type of Turbine Turbines at G.H.T.P.
1. Horizontal/Vertical Horizontal
2. Single/Multi-cylinder Multi-cylinder (3-cylinder)
3. Impulse/Reaction Impulse
4. Condensing/Non-condensing Condensing
5. Reheat/Non-reheat Reheat
6. Regenerative/Non- Regenerative With bypass (ST-1)
7. With bypass/Without bypass Without bypass (ST-2)

Page | 64
MAIN TECHNICAL DATA
a) The basic parameters:
Rated output measured at Terminal of the generator. 110.000KW
Economical output. 95.000KW
Rated speed. 3.000RPM
Rated temp.ofstearn just before the stop valve. 535C
Max Temp. of steam before the stop valve. 545C
Rated pressure of steam before the MP casing. 31.63C
Max. pressure of steam before the MP casing 35C
Rated temp.of steam before the MP casing. 535C
Max. temp. of steam before the MP casing. 545C
b) System of turbine:
4 Governing valves +2 interceptor valves HP cylinder- 2 Row Curtis wheel +8 moving

wheels.
Wt.Of HP rotor approx. 5,500 Kg.
MP cylinder - 12 Moving wheels.
Wt.Of MP rotor.Approx. 11,000 Kg.
LP cylinder - 4 Moving wheels of double flow design.
Wt.Of MP rotor approx. 24,000 Kg.
Direction of the turbine rotation - To the right, when looking at the turbine from the front
bearing pedestal.
Page | 65
TURBINE ASSEMBLY WITH LOWER CASING
TURBINE ACCESSORIES AND AUXILIARIES:
The following are turbine accessories and auxiliaries:
1. Surface condensers.
2. Steam jet air ejector
3. LP and HP heaters.
4. Chimney steam condenser.
5. Gland stearn condenser.
6. Oil purifier of centrifuge.
7. Clean oil pumps with clean oil tank.
8. Dirty oil pumps with dirty oil tank.
9. Auxiliary oil pump with aux. Oil tank.
10. Starting oil pumps.
11. Emergency oil pumps (AC and DC).

Page | 66
12. Jacking oil pumping.
13. Bearing or turning gear.
1. SURFACE CONDENSERS
Two no. surface condensers are used for condensing the steam which has worked
in the turbine. The coolant for condensing the steam is circulating water, which is inside
the condenser brass tubes, and steam is outside.
TECHNICAL DATA OF EACH CONDENSER:
Cooling area 3330 m2
No. of brass tubes 6000
Circulating water required for each condenser 7500T/Hr.
Circulating water required for both condenser2x7500T/Hr. 15000T/Hr.
Allowable difference between inlet & outlet C.W. water 10C Temp.
Vacuum in the condenser 0.90 Kg/cm2
2. STEAM JET AIR EJECTORS
Starting ejector or hogger is used for quick evacuation of the turbo set during
starting whereas main steam jet air ejector (Duplex Type) is used to maintain the
vacuum in the condenser. Steam Jet Air Ejector works on the principle of venture with
steam working media to eject air from the condenser.
3. STEAM HEATERS
In regenerative system there is a stream of 5 LP heater, one desecrator and 2 HP

heaters. All LP and HP heaters are of surface type i.e. condensate of feed water is inside
the heaters tubes and steam extractions are outside the heater tubes in the heater shells.
LP heaters are of single flow type whereas HP heaters are of double flow type i.e. feed
water is flowing twice through the HP heaters in order to extract total HP latent heat and
Page | 67
super heat of steam going into HP heaters, desecrator is a contact type heater in which
steam and condensate come in direct contact with each other.
Details of Steam Extraction:
Steam into HP heater NO. 2 is from cold reheat line.
Steam into HP heater NO.1 is from MP turbine, LPH- 4 LPH- 5 is from MP casing at
differently steam pressures and temperatures.
4. CHIMNEY STEAM AND GLAND STEAM CONDENSERS
There are the additional two heater stages provided in the regeneration system of
the turbine for heating the condensate flowing through it. Steam leak offs from the
turbine a gland is used for heating the condensate in these heaters.
5. STARTING OIL PUMPS AND ARRING GEAR
S.O.P supply necessary turbine oil during starting of the turbine and up to turbine
speed of 2930 RPM till the main oil pump mounted on the turbine rotor at the HP
extension.takes manually in order to provide lub. Oil for turbo set.
Emergency pumps (AC & DC) are meant to start on auto when turbine trips and
lub. Oil pressure falls in order to provide lubrication of turbine and generator bearings.
6. JACKING OIL PUMP AND ARRING GEAR
Jacking oil pump is used in order to lift the turbine rotor before it is put on
barring gear jacking oil pump takes suction from the turbine lub. Oil system and provide
a thin film of oil for lifting the rotor. Barring gear motor used to rotate the turbine rotor
at 62 RPM after engaging the rotor with the gear during starting and stopping of the
turbine.
7. CIRCULATING WATER PUMPS
Two nos. circulating water pumps provide for each unit circulate water @17200
tonnes per hour in a closer cycle comprising of turbine condenser and cooling tower. An
Page | 68
additional circulating water pump provide, serves as a stand by for two units. The water
requirement for bearingcooling of all plant auxiliaries is also catered by these pumps.
FUNCTION AND TYPES OF STEAM TURBINE

FUNCTION OF STEAM TURBINE
Steam turbine is a from of heat engine in which the available heat energy in from
of steam is converted into kinetic energy, to rotate the turbine rotor, by expansion of
steam in a suitable shaped nozzle, the pressure on the blades causing rotary motion is
purely dynamical and is due solely to the change of momentum of the steam jet during
its passage through these blades.
TYPES OF STEAM TURBINE

The steam turbines are broadly classified into three groups depending on the
conditions of operations of the steam on the rotor blades.
1) Impulse Type
This is again subdivided into:-
a) Simple Impulse
b) Compound Impulse
(Pressure, Velocity and Pressure & Velocity compounded)
c) Combined Impulse
2) Reaction Type
This is again grouped into:-
a) Axial Flow
b) Radial flow
c) Mixed flow
Page | 69
3) Impulse reaction Type
IMPULSE TURBINES
In an impulse turbine the potential energy in the steam due to pressure and
superheat is converted into kinetic energy in the form of weight and velocity by
expanding it in suitably shaped nozzles. The whole of the expansion takes place in the
fixed nozzles. The steam pressure at the inlet and outlet edges of the rotor blades are
equal as there is no expansion in the rotor bicycles. The steam impinges on the wheel I
blades causing the wheels to rotate. The expansion is carried out in stages referred to as
Pressure, Stages the commonest type of impulse turbine is the Delaval turbine.
REACTION TURBINE
In the type of turbines the steam expands in both the stationary and moving
blades. So, the steam pressure, at inlet to the moving blades is greater than the exit
pressure. The term reactions is strictly not correct as no turbine practice works on
pure reaction principle. The action on the balding is both impulse an reaction.
Page | 70
The steam turbine installed is a 3 cylinder,(HP r1v1p and LP r condensing, reheat cycle
type with 8 non~regulated extractions for regenerative heating pf the boiler feed water.
The cross section through a typical 110 MV1 steam turbine.
MEDIUM PRESSURE TURBINE
The low pressure turbine is split horizontally into three parts and all the parts are
connected by vertical flanges. The extreme parts of the L.P. turbine are connected
rigidly with surface condensers mounted on sturdy spring supports. The steam entering
the L.P. casing flows in both directions through 4 stages and finally exhausted into the
condenser. The middle part of the L.P. casing houses tube nests of first and second low
pressure heaters for heating the condensate.
The flanges of H.P., M.P. casings are designed to be heated by steam during the
starting up to turbine generator. By heating of the flanges, the differences in temperature
between the cylindrical portion of the casing, flanges and the connecting bolts are
reduced hence limiting the additional stresses on the bottles. The very important criteria
for starting and rate of loading the machine is the difference between the temperature of
Page | 71
the steam admitted in and that of the internals of the turbine. For the purpose of
measuring the temperature of the casing and the steam transfer piping there monopoles
are provided at appropriate points.
CONDENSATE AND BOILER FEED SYSTEM

The steam after doing the useful work in the turbine is exhausted into the
condensers where it is condensed by the cooling water (circulating water) flowing
through a network of tubes. After condensation, the condensate is collected in the hot
wells of the condensers. From the hot wells, the condensate is handled by the
condensate extraction pumps and is taken back to the closed loop system. Condensate
pump delivers the condensate into the deaerator through the main ejectors, chimney
steam condenser, gland steam condenser and low-pressure heaters. There are three
number of condensate extraction pumps of vertical turbine type installed for the above
purpose. The pump capacity of 160 T/hr and develops 215 MWC head. Under normal
conditions of operation of the unit (including full load condition) two pumps are
required to be kept in service while the third is a standby.
The condensate tapped off from the condensate extraction pumps discharge
header is utilized for the following services:-
1. Sealing of valves in the vacuum system. Condensate booster pump stuffing box
sealing.
2. L.P. gland sealing de-super heaters.
3. de-super heaters in the chimney steam condenser.
4. Cooler in the TG-exhaust.
5. Dilution of phosphate and hydrazine solutions.
The make up to the closed cycle is added at the condenser hot well by means of the
make up water pumps. There are 5 numbers D.M. transfer pumps installed which take
their suction from a D.M. water storage tank.
The condensate entering the desecrator under goes desecration process in which
all the dissolved gases in the condensate are removed to a greater extent and the
Page | 72
desecrated water is collected in the feed water tank which is an integral part of the
deaerator. The feed water tank is installed at a sufficiently higher elevation to provide a
positive suction to the boiler feed pumps.
The flow path of feed water is schematically shown in fig. The boiler feed pumps
(locted in the ground floor of the turbine hall) take their suction from the feed water
tank and deliver the feed water into the boiler drum through high pressure heater, feed
control station and economizer.
Two Nos. of boiler feed pump each of capacity- 445 /hr (8180 1 pm) developing
178 atm. head is installed. Out of two pumps, one pump is required to be kept in service
while the other one is a standby.
The feed control station consists of three branches of feed lines- a low load line
meant for up to 20% MCR and other two lines meant for 100% MCR conditions. (Out
of the two 100% MCR lines, one will be service while other is a standby).
The feed water for the de-super heaters of the SH and RH is tapped off before the
feed control station. Provisions are made to use the condensate booster pump for initial
filling of the boiler drum.
PROTECTIONS AND INTERLOCKS

The main turbine trip relay (TTX) energizes the turbine and trips the turbine
under the following conditions:-
1. Under frequency protection.

2. Generator shut-down energization.
3. Remote trip (P.B).
4. Generator distance relay actuation.
5.Generator negative sequence.
6. Generator transformer ground.
7. Generator loss of excitation.
Page | 73
8. Boiler master trip.
9. L.P.G. heater no.1 level high.(left or right: 775mm).
10.L.P. heater no. 2 level high (left or right: 775mm).
11.Axial shift thrust bearing high: ( 0.65mm).
12.Hydro mechanical protection axial shift very high: (0.85mm).
13.Primary governing oil pressure high: (3.05atm.).
14.Bearing oil pressure very low: (0.8atm.).
15.Main oil pump discharge very low: (7 atm.).
16.Exhaust pressure very high: (0.5 atm.).
EXPLANATION OF TURBINE SYSTEM :-
First of all the steam is generated in the steam generator i.e. boiler. From second
pass of the boiler the steam is generated at 530C and at a pressure of 110 kg/cm 2
enters the high pressure turbine. The steam works i.e. expands along the rows of blades
and the prime mover i.e. turbine starts moving. After working in the high pressure
turbine the steam again enters the second pass of the boiler for reheat. All the turbines
are coupled to a single rotor. The high pressure turbine is of reaction turbine, horizontal
type multicylinder. In reaction turbine the steam expands continuously as it passes over
the rows of blades and thus there is gradual fall in pressure during expansion.
The steam from high pressure turbine enters the second pass of boiler for reheat
at 30kg/cm2 at 360C. After reheating the steam again enters the medium pressure
turbine at 28 kg/cm2 . The temperature of the steam entering the medium pressure
turbine is 530C. After working the steam leaves the medium pressure turbine is of
impulse type. In impulse turbines steam expands in the nozzles and its pressure does not
alter as it moves over the blades. So the pressure of the steam entering the MP and
leaving MP remains 28kg/cm2. With in the casing of the MP.Number of tappings namely
4,5,6,7 are made for low pressure heaters. Tapping number six is the dummy tapping.
Tapping number 5 from the MP turbine goes to the LP turbine goes to the heater
NO. 2. The condensate of all the three LPHs goes to the deaerator. Tapping no.7 from
MP turbine goes to high pressure heater no.2, HPH no.1 gets connection from the cold
Page | 74
reheat from the high pressure turbine. The condensate of the high pressure heaters goes
to the economizer. The outlet temperature of condensate from HPH is 240C. From the
deaerator after deaerator the condensate through boiler feed pump goes to HPHs from
where this enters to economizer.
From the MP turbine the steam enters the LP turbine. After working, the steam
enters the condenser, four LPHs are also placed within the casing of the LP turbine. The
condensate from these heaters through a single pipe enters the ejector, fromwhere the
condensate enters the chimney steam condenser and then to the gland steam condenser
through which the condensate enters the HPHs and then goes to economizer. The steam
leaves the LP turbine at -0.90 kg/cm2 i.e. it works under vacuum.
The work of the ejector is to create vacuum. The condensate from the ejector
enters the main steam to the condenser. After condensation the condensate entersthe
condensate enters the well of the condenser which is at 45C. One tapping from the well
goes to the ejector. a level of the water is maintained in the well. The condensate from
the gland steam condenser and chimney steam condenser enters the water well.
With in the medium pressure turbine a dummy tapping is there. The steam enters
this turbine at 530C from two sides. The pressure of steam is 28 kg/cm2.
The cold reheat from the HP turbine enters the second pass of the boiler. The
turbine speed is controlled by electro-hydraulic governing device, from where
governing is done.
CONSTRUCTION OF TURBINE :-
The turbine is a tandem compound machine with HP, IP and LP parts. The HP
part is single flow cylinder and IP and LP parts are double flow cylinders. The
individual turbine rotors and the governor rotors are connected by rigid couplings.
In designing the supports for the turbine on the foundation, attention is given to
the expansion and contraction of the machine during thermal cycling. Excessive stresses
would be caused in the components if the thermal expansion or contraction were
Page | 75
restricted in any way. The method of attachments were restricted in any way. The
method of attachments of the machine components and their coupling together are also
decisive factors in determining the magnitude of the relative axial expansion between
the rotor system and turbine casing.
CASING EXPANSION :-The front and rear bearing housing of the HP turbine can
slide on their base plates in an axial direction. Any lateral movement perpendicular to
the machine axis is prevented by fitted keys. The bearing housings are connected to the
HP and IP turbine casing by guides which ensures that the turbine casing maintain the
central position while at the same time allowing axial movement. Thus the origin of the
cumulative expansion of the casing is at the front bearing housing of the IP turbine.
ROTOR EXPANSION :-
The thrust bearing is in corporated in the rear bearing housing of the HP turbine.
Since this bearing housing is free to slide on the base plate. The shafting system moves
with it. Seen from this point both the rotors and casing of the HP turbine expand
towards the front bearing housing of the HP turbine. The rotor and casing of the IP
turbine expand towards the generator in a similar manner.
DIFFERENTIAL EXPANSION :-
Differential expansion between the rotor and casing results from the difference
between the casing expansion. Originally from the bearing housing behind the IP
turbine.
CONSTRUCTION OF TURBINE(HP) :-
Casing :- Barrel type without axial joint. An axially split guide blade carrier is arranged
in the barrel type casing suitable for quick start up and loads.
Blading :-The HP turbine blading consists of several stages. All the stages are reaction
stages with 50%.
Page | 76
ELECTROSTATIC PRECIPITATOR
WORKING PRINCIPLE OF ESP

The electrostatic precipitator installed at GHTP,Bathinda units to extract dust,
utilizes electrostatic forces to separate dust particles from the gas 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. A frame with secured wires
Page | 77
is located within each passage. All the frames are linked to each passage. The frames are
linked to each other to form a rigid framework.
The entire frame works is held in place by four support insulators, which is
electrically from all, which are grounded.
A high voltage direct current is applied between the framework the ground
thereby creating a strong electrical field between the wires in the framework and the
steel curtains. The electrical become strongest near the surface of the wires, so strong
that an electrical discharge. The corona discharge develops along the wires. The gas is
ionized in the corona discharge and large quantity of positive and negative ions are
formed. The positive ions are immediately attracted towards the negative wires by the
strength of the field indicate the negative ions however have to traverse the entire space
between the electrodes to reach positive curtains.
Enroute towards the steel curtains, the ions collide and adhere 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 the gravitational force on the particle. The speed of
migration towards to steel curtains is therefore much greater than the speed of
sedimentation in free fall.
Page | 78
MECHANICAL SYSTEM
1) HOPPER :-
The hoppers are sized to hold the ash for 8 hours. Collection, buffet plates are
provided in each hopper to avoid gas leakage. Inspection door is provided on one side
of hopper wall. Thermostatic controlled heating elements are arranged at the bottom
portion of the hopper to ensure free flow of ash.
Page | 79
HOPPER
2) GAS DISTRIBUTION SYSTEM
The good performance of the precipitator depends on even distribution of gas
over the entire cross section of the field. As the expands ten-fold while entering the
precipitator, guide vanes, splitters and screens are provided in the inlet funnel to
distribute the flue gas evenly over the entire cross section of the E.P
Page | 80
3) COLLECTING ELECTRODES SYSTEM
The collecting plates are made of 1.6 mm cold rolled mild steel plate and shaped in
one piece by roll forming. The collecting electrodes have unique profile with a
special configuration on its longitudinal edges. This profile is designed to give
rigidity and to contain the dust in a quiescent zone free from retainment. The
collecting plates are provided with hooks at their top edges for suspension. The hooks
engage in slots of the supporting angle. All the collecting plates in a row are held in
position by a shock bar at the bottom. The shock bars are spaced by guides.
4) EMITTING ELECTRODE SYSTEM
The most essential part of precipitator is emitting electrode system. This is

supported by four insulators. The frames for holding the emitting electrodes are
located centrally between collecting electrodes curtains. The entire discharge frames
are welded to form a rigid box like structure.the emitting electrodes are kept tight
between the frames.
5) RAPPING SYSTEM
Rapping mechanism is provided for collecting and emitting electrodes. The
rapping mechanism is driven by geared motors. The rapping system employs
tumbling hammers, which are mounted on a horizontal shaft. As the shaft rotates
slowly the hammers tumble on to the shock bar/shock beam which transmits blow to
the electrodes. One complete revolution of the rapping shaft will clean th entire field.
The rapper programmer decides the frequency of rapping. The tumbling hammers
disposition and the periodicity of rapping are selected in such a way that less than
2% of the collecting area is rapped at one time. This rapping shaft of emitting
electrodes system is electrically from the geared motor driven by a shaft insulator.
The space around the shaft insulator is continuously heated to avoid condensation.
ELECTRICAL SYSTEM
1) High Voltage Transformer Rectifier (HVR) with Electronic Controller (EC) :-

The rectifier supplies the power for ash particle charging and collection. The basic
function of the EC is to feed the precipitator with maximum power input under
constant current regulation. Should there be any flash between collecting and
Page | 81
emitting electrodes, the EC will sense the flash and quickly react by bringing the
input period voltage to zero and blocking it for a specific period. After the ionized
gases are cleared and the dielectric strength restored, the control will quickly bring
back the power to a preset value and raise it to the original non sparking level. Thus
the EC ensures adequate power input to the precipitator while arresting the electrical
disturbances with in the precipitator. Regulated AC power from EC is fed to the
primary of the transformer, which is stepped up and rectified to give a full wave
power output. The transformer is mounted on roof of the precipitator while the EC is
an air conditional control room.
2) Auxiliary Control Panel (ACP)
The ACP houses the power and control circuits required for energizing rapping
motor and heating elements of the precipitator. One ACP controls each gas path. The
complete ACP is of modulator type with individual module for each feeder. Each
module houses the power and control with meters. Push buttons, switch and
indicating lamps are mounted on the door of the compartments.
FLY ASH DISPOSAL
At GNDTP, Bathinda there are two systems used for the disposal of fly ash :-
Wet system
Some portion of ash is supplied to the Ambuja Cement Factory
WET SYSTEM :-
As mentioned earlier, the fly ash is collected in new ESPs and old ESPs hoppers.
The ash from these hoppers is sucked in fly ash lines (suction is provided by
hydrovector). Hydrovector is sort of water ejector, at one end of which HP water
enters and the other end is connected to flue ash line running under the hoppers and
then to collecting tank (wetting head), where ash is mixed with LP water and the
mixture of ash and water falls by gravity into the ash slurry sump. Ash slurry pump
discharges the slurry from the sump to disposal area
MAXIMUM PERFORMANCE OF ESP :-
The performance of the ESP is influenced by a number of factors many of which
may be controllable. It should be the aim of every operator to maximize the
performance by judiciously adjusting the controllable variables.
CLEANING OF ELECTRODES :-
Page | 82
The performance of the ESP depends on the amount of electrical power absorbed by
the system. The highest collection efficiency is achieved when maximum possible
electric power for a given set of operating conditions is utilized on the fields. Too
thick a dust layer on the collecting plates will lead to drop in the effective voltage,
which consequently reduces the collection efficiency. It also leads to unstable
operating conditions. Therefore the rapping system of collecting and emitting
electrodes should be kept in perfectly working condition. All the rapping motors
have been programmed to achieve the optimum efficiency.
SPARK RATE :-
The operating voltage and current keep changing with operating conditions. The
secondary current of HVRs have been set just below the spark level, so that only
few sparks occur during an hour. Spark rate between 5 to 10 sparks per minute is the
most favourable limit, as per the practical experience. Too high flash over rate will
not only result in reduction in useful power and interruption of precipitation process
but will cause snapping of emitting electrodes due to electrical erosion.
CONTROLLING THE SPARK RATE :-
One number s-pot and one number t-pot have been provided on the front of each
electronic controller. The s-pot controls the drop rate of rise of field current after the
spark is over. The operator can control the rate of spark by adjusting these two pots
manually. Both the pots if turned anticlockwise will cause increase in spark rate.
ASH HOPPER EVACUATION :-
Improper/incomplete hopper evacuation is a major cause for the precipitator
malfunction. If the hoppers are not emptied regularly, the dust will build upto the
high tension emitting system causing misalignment of the electrodes. Though the
hoppers have been designed for a storage capacity of 8 hours, under MCR
conditions, this provision should be used only in case of emergency. Normally, the
hopper should not be regarded as storage space for the collected ash.
OIL COMBUSTION :-
The combustion of oil used during start up or for stabilization of the flame can have
an important impact on precipitator operation. Unburnt oil, if passed into ESP can
deposit on the emitting and collecting electrodes and deteriorates the electrical
conditions i.e. reduce the precipitators operating voltage due to high electrical
resistivity and consequently the ESPs performance is affected adversely. The
precipitator performance remains poor until the oil vaporizes and the ash layer gets
rapped-off, which usually takes along time.
AIR CONDITIONING OF THE ESPS CONTROL ROOM :-
Page | 83
The ESPs control room houses sophisticated electronic controllers. The operation of
these controllers directly reflects on precipitator performance. In order to ensure that
the controllers are in proper working conditions, it is essential to maintain a dust free
atmosphere with controlled ambient conditions. Therefore, the air conditioners
should be kept in proper working conditions.
Page | 84
ASH HANDLING
DISPOSAL OF ASH
The disposal of ash is an important aspect in the working of whole cycle. As the coal
is burnt, its residue is obtained in the form of ash. The amount of ash is quite large
since its disposal has to be worked out. As coal used in the boiler has 40% ash hence
ash obtained is 2500 tonnes per day at full load from all the four units as each unit
consumes 1400 tonnes of coal per day. The ash obtained is of two types:-
1. Wet ash
2. Dry ash
1. Wet ash is collected at the base of the boiler. When coal is burnt in the powered form,
some particles, which are heavier and are known as clinkers falls at the base. At the
base boiler water is stored in a trough like arrangement and boiler particles fall in it
and after some time a mixture known as slurry is formed this type of ash obtained is
wet ash. This ash is cleared with the help of jets of water, which comes out of the
nozzles from all sides. This water is provided with pressure pump and this mixture is
carried by piping system to a slurry tank. Wet ash is cleared off 8 hours and this
Page | 85
process takes about 20-30 minutes.
Wet ash
2. The other type of ash is dry or fly ash, which moves along with flue gases as it is
sucked by vacuum, created by the I.D. fan the flue gases are made to pass through
the mechanical precipitators. In these coarse ash particles get separated out by
centrifugal action. Then these coarse ash particles get separated out by centrifugal
action. Then these are made to pass through high voltage electric field where final
ash particles are made to pass through high voltage electric field where these get
Page | 86
ionized and are collected towards the collecting electrodes. The ash particles are
removed from the electrodes by the hammer type arrangement, which strike on
the electrodes after regular interval and ash falls below in the hopper
arrangement. The fly ash is disposed from the hopper to pneumatic system
vacuum system. This vacuum is obtained by passing of water through nozzles by
H.P. pumps. When vacuum is created, the ash in the hopper is carried along with
air through with air through the pipes and is mixed with water to form slurry and
afterwards it is carried to slurry tank. This water is provided by L.P. pump.
Circuit Diagram Of Ash Handling System
The hopper can be cleaned after regular interval of time or whenever required. From the
slurry tank, the slurry is disposed to a distance of about 6-7 kg/cm. The ash disposal
area is about 850 Acres. From this slurry, the disposed water is absorbed by soil and fly
ash remains as it is.
Due to modern technology developed so far, now this ash is being used to make
cement by Ambuja Cement Industry. Bricks can also be made from this ash and the
bricks made from the ash are of higher properties than the bricks obtained from other
sources.
Page | 87
The flue gases are finally let off through chimney to atmosphere due to draught
created by I.D. fan. The ash content disposed off along with flue gases is about 3-5%.
About 20% of the ash falls out in the bottom ash hopper of the boiler and is periodically
removed, mechanically. The remainder of the ash is separated from, flue gases in the
mechanical and electrostatic precipitators and as discussed above.
CONCLUSION
Spending my six months of training in Guru Hargobind Thermal Plant,
LehraMohabbat,Bathinda. I concluded that this is a very excellent industry of its own
type. They have achieved milestones in the field of power generation. They guide well
to every person in the industry i.e. trainees or any worker. I had an opportunity to work
in various sections namely Switch Gear, Boiler section, Electrostatic precipitator (ESP) ,
De-mineralized water plant, Coal Plant, Switch Yard etc. while attending various
equipments and machines. I had got an endeverous knowledge about the handling of
coal, various processes involved like unloading, belting, crushing and firing of coal. The
other machines related to my field that I got familiar with boiler,ESP (EPIC-II ,RTU)
etc. I found that there existed a big gap between the working in an institute workshop
and that in the industry. Above all the knowledge about the production of electricity
from steam helped me a lot to discover and sort out my problems in my mind related to
the different equipments present in the thermal plant. The training that I had undergone
in this industry will definitely help me to apply theoretical knowledge to the practical
situation with confidence.
Page | 88
BIBLIOGRAPHY
1. A course in electrical & electronic measurement and instrumentation: -
A.K.SAWHNEY
2. www.wikipedia.com
3. www.google.com
4. Manuals of different departments of GURUHARGOBIND THERMAL PLANT
LEHRA MOHABBAT, BATHINDA
Page | 89

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G.H.T.

Guru Hargobind Thermal Plant

BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING

PTU GZS CAMPUS,

and esteemed personality Dr.Balwinder Singh under whose expert guidance we

work of training and project work.

We are also thankful to the Technical Training Cell (T.T.C) at

G.H.T.P.LehraMohabbat, Bathinda who introduced us to the problem and provided

were instrumental in providing us with various lines to think on.

helped us a lot in completing our project successfully.

GURU HARGOBIND THERMAL PLANT

generated by Unit-4 during stabilization period before its commercial operation)

amongst all state sector power plants during 2008-09.

savingCrores of rupees, which speaks of high plant performance at which the

plant load factor at any plant of PSPCL.

savingRs. 30 Crores approx. was done in terms of power purchase.

The new records set by GHTP LehraMohabbat during 2009-10 are as

National highest 95.99%

achieved by GHTP Stage-I

units during 2008-09.

Highest ever annual generation: 7515.2 MU 5610.09MU in 2008-09

Highest ever annual plant load factor:96.44% 95.10% in 2007-08

Highest ever annual plant utilization factor: 100.38% 100.31% in 2007-08

Highest ever annual deemed plant load factor: 97.53%97.07% in2003-04

Lowest ever annual Auxiliary Cons. (%):8.23%8.71% in2008-09

Plant performance and energy consumption:

The following benefits have been accrued to GHTP as a result of implementation of

innovations / best practices to improve the energy efficiency of GHTP:

GHTP has achieved thermal efficiency of 35.52% during 2009-10 against a

target of 34.40% set up by Punjab State Electricity Regulatory Commission.

Auxiliary consumption of GHTP remained at its lowest ever value of 8.23%.

resulted in reduction of nearly 13 Amperes of current on 6.6 KV on each running

3) Installed Capacity unitwise 2 x 210 =420 MW

5) Executing Agency TATA HONFY WELL AND BHEL

6) Clearances Status Cleared by CEA, New Delhi. Investment

8) Synchronization dates Unit-1 : DECEMBER 1997

9) Annual Generation at 68.5% 3000 MU 2715 MU Net

10) Coal consumption / year

11) Cost of Generation 112 Paisa/Kw

3) Installed Capacity unitwise 2 x 250 = 500 MW

4) Type of Fuel Coal

5) Executing Agency BHEL

6) Clearances Status Cleared by CEA, New Delhi. Investment

7) Total estimated Cost Rs. 2123 Crores.(approx.)

8) Synchronization dates Unit-3 Commercial Operation date (COD)16-

11) Cost of Generation Rs. 3.17 ( at Bus Bar).

ELECRICITY GENERATION PROCESS EXPLANATION

REHEATER SYSEM (RH)

ECONOMISER SYSTEM (ECON)

BOILER FEED PUMP (BFP)

CONDESATE EXTRACTION PUMP (CEP)

GLAND STEAM COOLER (GSC)

DRAIN COOLER (DRN CLR)

LP HEATERS (LP HTRS)

H.P. HEATER (HP HTRS)

ROTARY AIR HEATER (RAH)

FORCED DRAFT FANS (FD FAN)

INDUCED DRAFT FANS (ID FANS)

ELECTROSTATIC PRECIPETATORS (ESP)

Disributioncenter distributes from here to Barnala Sub Distribution Mansa, Bathinda,

RAW MATTERIAL AND THEIR SOURCES

Water is taken from Sirhand canal by the tunnel link of underground

COAL HANDLING PLANT

The main companies, which provide coal to the Plant, are: