Industrial Training

Report
On
Water Treatment and Coal
testing
At
Guru Nanak Dev Thermal
Plant
Bathinda

Submitted By:
Mahinder Singh
UE89034
 Under the guidance of

Mrs.
Er.
Mechanical Dptt.
Add. S.E. T.T. cell

GNDTP, Bathinda

Department of Mechanical
Engineering
U.I.E.T. PANJAB UNIVERSITY,
CHANDIGARH
ACKNOWLEDGEMENT

DECLARATION

I hereby declare that the project work entitled Water treatment

and coal testing is an authentic record of my own work carried
out at Bathinda as requirements of six months Industrial Training
for the award of the degree of B.E. at University Institute of
Engineering & Technology, Panjab University, Chandigarh under
the guidance of Er. T.N.Bansal and Mrs. Anjali Gupta, during 1jan-
24May 2012.
 student

Date: 28May2012

Certified that the above statement made by the student is correct

to the best of our knowledge and belief.

Mrs. Er.
Mechanical Dptt. Add.
S.E. T.T.cell
UIET
GNDTP, Bathinda

INTRODUCTION

Guru Nanak Dev Thermal Power Plant is a coal-based plant.

The requirement of coal for four units based on specific fuel
consumption of 0.60 kg / kWh . The conveying and crushing
system will have the same capacity as that of the unloading
system. The coal comes in as large pieces. This coal is fed to
primary crushers, which reduce the size of coal pieces from
400mm to 150mm. Then the coal is sent to secondary crusher
through forward conveyors where it is crushed from 150mm to
20mm as required at the mills. Then the coal is sent to boilers
with the help of primary fans. The coal is burnt in the boiler. Boiler
includes the pipes carrying water through them; heat produced
from the combustion of coal is used to convert water in pipes into
steam. This steam generated is used to run the turbine. When
turbine rotates, the shaft of generator, which is mechanically
coupled to the shaft of turbine, gets rotated so, three phases
electric supply is produced.

The basic requirements are:-

Fuel (coal)
Boiler
Steam turbine
Generator
Ash handling system
Unit auxiliaries

HISTORY
.
Due to high rate of increasing population day by day, widening
gap between power demand and its availability was one the basic
reason for envisaging the G.N.D.T.P. for the state of Punjab. The
other factors favoring the installation of the thermal power station
were low initial cost and comparatively less gestation period as
compared to hydro electric generating stations. The foundation
stone of G.N.D.T.P. at bathinda was laid on 19 th November 1969,
the auspicious occasion of 500th birth anniversary of great Guru
Nanak Dev Ji.
The historic town of bathinda was selected for this first and
prestigious thermal project of the state due to its good railway
connections for fast transportations of coal, availability of canal
water and proximity to load center.

The total installed capacity of the power station 440MW with

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

Coal received from collieries in the rail wagon is

mechanically unloaded by Wagon Tippler and carried by belt
Conveyor System Boiler Raw Coal Bunkers after crushing in the
coal crusher. The crushed coal when not required for Raw Coal
Bunker is carried to the coal storage area through belt conveyor.
The raw coal feeder regulates the quantity of coal from coal
bunker to the coal mill, where the coal is pulverized to a fine
powder. The pulverized coal is then sucked by the vapour fan and
finally stored in pulverized coal bunkers. The pulverized coal is
then pushed to boiler furnace with the help of hot air steam
supplied by primary air fan. The coal being in pulverized state
gets burnt immediately in the boiler furnace, which is comprised
of water tube wall all around through which water circulates. The
water gets converted into steam by heat released by the
combustion of fuel in the furnace. The air required for the
combustion if coal is supplied by forced draught fan. This air is
however heated by the outgoing flue gases in the air heaters
before entering the furnace.

The products of combustion in the furnace are the flue gases

and the ash. About 20% of the ash falls in the bottom ash hopper
of the boiler and is periodically removed mechanically. The
remaining ash carried by the flue gases, is separated in the
electrostatic precipitators and further disposed off in the ash
damping area. The cleaner flue gases are let off to atmosphere
through the chimney by induced draught fan.

The chemically treated water running through the water

walls of boiler furnace gets evaporated at high temperature into
steam by absorption of furnace heat. The steam is further heated
in the super heater. The dry steam at high temperature is then led
to the turbine comprising of three cylinders. The thermal energy
of this steam is utilized in turbine for rotating its shaft at high
speed. The steam discharged from high pressure (H.P.) turbine is
returned to boiler reheater for heating it once again before
passing it into the medium pressure (M.P.) turbine. The steam is
then let to the coupled to turbine shaft is the rotor of the
generator, which produces electricity. The power from the
generator is pumped into power grid system through the
generator transformer by stepping up the voltage.
The steam after doing the useful work in turbine is condensed to
water in the condenser for recycling in the boiler. The water is
pumped to deaerator from the condenser by the condensate
extraction pumps after being heated in the low pressure heater
(L.P.H) from the deaerator, a hot water storage tank. The boiler
feed pump discharge feed water to boiler at the economizer by
the hot flue gases leaving the boiler, before entering the boiler
drum to which the water walls and super heater of boiler are
connected.

The condenser is having a large number of brass tubes

through which the cold water is circulated continuously for
condensing the steam passing out sides the surface of the brass
tubes, which has discharged down by circulating it through the
cooling tower shell. The natural draught of cold air is created in
the cooling tower, cools the water fall in the sump and is then
recirculated by circulating water pumps to the condenser.

PLANTS SALIENT
FEATURES

PROJECT AREA:-

Power plant 238 acres

Ash disposal 845

Lake 180

Residential colony 285

Marshalling yard 256

Total area 1804

TOTAL COST:- Rs. 115 crores

STATION CAPACITY:- four units of

110MW. Each

BOILER:-
Manufacturers B.H.E.L.

Maximum continuous rating (M.C.R.) 375 T/hr.

Superheater outlet pressure 139 kg/cm

Reheater outlet pressure 33.8 kg/cm

Final superheater/reheater temperature 540C

Feed water temperature 240C

Efficiency 86%

Coal consumption per day per unit 1400 tones

(Approximate)

STEAM TURBINE:-
Manufacturers B.H.E.L.

Rated output 110 MW.

Rated speed 3000 r.p.m.

Number of cylinders three

Rated pressure 130 kg/cm

Rated temperature 535C

Condenser vacuum 0.9 kg/cm

GENERATOR:-
Manufacturers B.H.E.L.

Rated output

(Unit- 1 & 2) 125000KVA

(Unit -3 & 4) 137000KVA

Generator voltage 11000 volts

Rated phase current

(Unit 1 & 2) 6560 Amps.

(unit 3 & 4) 7220 Amps.

Generator cooling hydrogen

BOILER FEED PUMPS:-

Number per unit two of 100% duty each

Type centrifugal

Rated discharge 445 T/hr.

Discharge head 1960 MWC.

Speed 4500 r.p.m.

 CIRCULATING WATER PUMPS:-
Numbers for two units five of 50% duty each

Type mixed flow

Rated discharge 8600 T/hr.

Discharge head 24 MWC.

COOLING TOWERS:-
Numbers four

Water cooled 18000 T/hr.

Cooling range 10C

Height 120/122 metres

COAL PULVERISING MILLS:-

Numbers three per unit

Type drum-ball

Rated output 27 T/hr.

Coal bunkers 16 per unit

RATING OF 6.6 KV AUXILLIARY MOTORS:-

Coal mill 630 KW

Vapour fan 320 KW

C.W. Fan 800/746 KW

Coal crusher 520 KW

Primary air fan 320 KW

Forced draught fan 320 KW

Boiler feed pump 3500 KW

Induced draught fan 900/1000 KW

Condensate pump 175 KW

DIFFERENT CELLS OF
PLANT

CHP (Coal Handling Plant)

The G.N.D.T.P. units are primarily coal-fired units and the coal
consumption at maximum continuous rating (M.C.R.) per unit is
about 58 T/Hr. the coal used at G.N.D.T.P. is of bituminous and
sub-bituminous type and this is received from some collieries of
M.P. and Bihar.
UNLOADING OF COAL:-
In order to unload coal from the wagons, two Rotaside
Tipplers of Elecon make are provided. Each is capable of
unloading 12 open types of wagons per hour. Normally one tippler
will be in operation while the other will be standby. The loaded
wagons are brought to the tippler side by the loco shunters. Then
with the help of inhaul beetle one wagon is brought on the tippler
table. The wagon is then tilted upside down and emptied in the
hopper down below. The tippler is equipped with the integral
weighbridge machine. This machine consists of a set of weighing
levers centrally disposed relative to tippler. The rail platform rests
on the weighing girders and free from rest of the tippler when the
wagon is being weighed. After weighing the loaded wagons is
tipped and returned empty to the weighing girders and again
weighed. Thus the difference of the gross weight and the tare
weight gives the weight of the wagon contents. The tipplers are
run by motors of 80 H.P. each through gears only.

IMPROVED DESIGN OF WAGON TIPPLER :-

We under the new scheme, propose to raise the level of

hopper to the ground level. Correspondingly, the level of the
platform of wagon tippler will also have to be adjusted. Also the
building structure covering the hopper and tripper will be done
away with keeping the hopper open. In this way the screen of the
hopper becomes accessible to pay loader trucks. Now, when the
screen gets blocked, a pay loader truck can be employed which
will lift all the over sized coal and take it to a suitable place where
it can be broken either manually or by a crusher. Thus it will save
time as the trolleys can be emptied faster, saving damages.

USE OF LOAD CELL TYPE WEIGHBRIDGE FOR WEIGHMENT

IN MOTION :-

Load ceil type weighbridges are sometimes called dynamic

weighbridge because the wagons can be handled over them at a
maximum speed of up to 12 m.p.h. They consists of two platforms
one for gross and one for tare weights. Each wagon weight is
automatically printed out and so is the railway loop. First the
gross weights are established and memorized, then the train is
moved over the rail track hopper for discharge, after the empty
train is moved out over the tare weighbridge platform where the
tare weights are printed out. Finally the total net weight is
computed and printed out. The load cells at each weighbridge are
connected to a digitizer suitable for converting the analogue
output of the load cell into digital form.
 Wagon Tippler

When coal reaches the plant, normal size of coal is about 500mm
primary crusher 120mm secondary crusher 25mm
coal mill pulvarised coal ,feeded in boiler.

Before this boiler is preheated with oil upto 350 0c,then oil supply
is cut down.
Conveyer Belt
Boilers
It is a single drum, balanced draught, natural circulation, reheat
type, vertical combustion chamber consists of seamless steel
tubes on all its sides through which water circulates and is
converted into steam with the combustion of fuel. The
temperature inside the furnace where the fuel is burnt is of the
order of 1500C. The entire boiler structure is of 42meter height.

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

Boilers burn the fuel transferred from the tank and use the
resulting heat to convert water into steam. Inside the boilers are
tens of thousands of water-carrying tubes. When combustion
commences, the temperature inside the boilers rises to between
1,100 and 1,500C, the water inside the tubes is turned into high-
temperature and high-pressure steam, and the steam is
transferred to the steam turbines.
CIRCULATING WATER PUMP:-
Two nos. of circulating water pumps provided for each unit,
circulate water at the rate of 17200 T/hr. in a closed cycle
comprising of Turbine Condenser and Cooling Tower. An additional
Circulating Water Pump provided serves by for two units. The
water requirement for bearing cooling of all the plant auxiliaries is
also catered by these pumps.

Boiler
 Boiler specifications

Feed water temperature 240C

Final super heater/reheater temperature 540C
Super heater outlet pressure 139kg/cm
Efficiency 86%
Coal consumption per day per unit 1400 tones
(Approximate)

Turbines
The steam rotates the turbine blades at a high speed of 3,000
rpm. This turns the power generator, which is directly connected
to the turbines, and electricity is produced as a result. This
electric power is then delivered along power transmission lines
and through substations to the homes of customers.

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:-

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.N.D.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)

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. of stearn 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.

General Specifications of Turbine

Manufacturers B.H.E.L.

Rated output 110 MW.

Rated speed 3000 r.p.m.

Number of cylinders three

Rated pressure 130 kg/cm

Rated temperature 535C

TURBO-GENERATOR:-
The hydrogen-cooled generator is directly coupled to the
turbine shaft rotating at speed of 3000 rpm generating electricity
at 11000 volts. The turbine is horizontal, three casings, reheat,
steam condensing, regenerative and of impulse type equipped
with a precise oil operated speed governor. The generated voltage
is stepped by unit power transformer to state grid system.

Circulating water pump:-

Two nos. of circulating water pumps provided for each unit,

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

NEED OF A 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.

TYPES:- There are two broad classifications:-

a) Direct contact type condenser:- where the condensate and

cooling water directly mix and come out as a single
stream.
b) Surface condenser:- which are shell and tube heat
exchangers where the two fluids do not come in direct
contact and heat released by the condensation of steam is
transferred through walls of the tubes into the cooling
water continuously circulating inside them.
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

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

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.
CHIMNEY STEAM CONDENSER:-
It is a sort of heater in which waste chimney steam, taken from
the outer leaks of the gland seals of H.P., M.P. and L.P. cylinders of
the turbine, is utilized in heating up the main condensate. The
drip of chimney steam condenser is generally mixed with air and
is collected in impure condensate tank from where it is pumped to
floor drains.

GLAND STEAM CONDENSER:-

It is also a sort of heaters, steam to gland steam condenser is
taken from inner leaks of the sealing glands of H.P. and front
gland of M.P. cylinders of the turbine and after heating the main
condensate, the drip of gland steam condenser being pure, is
directly taken to the hot well.
Cooling towers:-

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

WORKING PRINCIPLE OF ESP

 The electrostatic precipitator installed at GNDTP,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 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.

The fly ash carried by outgoing flue gases is arrested at two

stages. In the mechanical precipitators, the coarse ash particles
are separated out by centrifugal action. In the Electrostatic
Precipitators, the finer ash particles in the flue gases are made to
pass through high voltage electric field, where these particles get
ionized and are attracted towards the collecting electrodes. The
dry ash is collected in the hoppers underneath and further
deposited off in Ash Disposal Area.
 Project

Water treatment and Coal

testing

Boiler is the heart of thermal plant, its main purpose is to convert

water into steam.

N a t u r a l w a t e r i s a v a i l a b l e i n abundance, but it contains

impurities in many forms which are as following types.

Types of impurities.
 Water hardness is primarily because of calcium and
magnesium minerals, and hardness is responsible for
scale formation.

Carbonates or temporary hardness- Ca and Mg

bicarbonates are responsible for alkaline hardness, but
on applying heat release CO2 and form soft scale.

Non-Carbonates or permanent hardness- due to presence of

salt of calcium and magnesium but in form of sulphates and
chlorides. On applying heat these ppt. out and form
hard scale, which is diffi cult to remove.

Water Alkalinity is because of bicarbonates,

carbonates.

Alkalinity can convert to CO2 in steam. This

causes corrosion.

When pH is below the recommended range chances of

corrosion increases, and when it is above
recommended value then chances of scaling increases.

Boiler scale lowers heat transfer due to low thermal

conductivity. Heat transfer may be reduced as much as
5-10% by the presence of scale.
Due to scaling following are the negative eff ects on
the working of plant

a. increased fuel bill by decreasing the operating efficiency

b. thermal damage
c. increased cleaning time and cleaning costs
d. reduced working life of a boiler.

Pre Treatment of
Water

Canal water

Lake- Lake- Lake-

Intake pump
house
 Clarifier (Alum
dosing)

Clear well

To make water free from suspended, colloidal and organic

impurities, process involved in pre-treatment are:-

A) Settling and Coagulation-

Coagulant (turbidity, micro-organisms) reacts with the

alkalinity of the water to form a gelatinous precipitate
 Clear well

Pump
Clear well

iii ii i
 Sand Filters

Sand filters
B) Filtration-

Passage of fluid through a porous medium using sand filter

arrangement to remove matters holding suspension.

1. Suspended silt

2. Clay

3. Colloids

4. Micro organisms including algae, bacteria and virus

 Demineralisation
System

The process of demineralisation water by ion exchange

comprises of:-

Conversion of salts to their corresponding acids by

hydrogen cat-ion exchanger.

Removal of acids by anion exchangers.

The two exchangers are normally in series. Normally cat-ion

precedes the anionexchanger

Major ion exchange materials are synthetic resins made by the

polymerization of various organic compounds, resins have strong
affinity to attract the +ve charge towards itself.

Most frequently used compounds are:-

1. Styrene

2. Die vinyl Benzene

DM Plant Layout
 Cation exchanger mainly removes Calcium, Magnesium,
sulfates, chloride, nitrates and sodium salts alkalinity from
raw water.

In cation exchanger positive ion of the salt is exchanged

by the
H+ ion
On discharging, it is charged with 400Kg of 30%Hcl.

Cation Exchanger
 Carbon dioxide generated by dissociation of carbonic acid at
cation outlet water, is removed by degasser system.

Water from outlet of cation exchanger is made to fall

from a height, and a pressurized air is blown upstream
of the water flow to separate gases.

Degasser Blower

Degasser
Tank
 Anion exchangers remove the highly dissociated acids (like
H2So4, HNo3,

Hcl) from the effluent of cation exchanger.

In anion exchanger negative charged part of the salt is

exchanged by the OH- ion.
On discharging, it is charged with 200Kg of
47.5%NaOH.

Anion Exchanger
 Mixed-bed
Deionisation
Effluent water after anion exchanger may still have some salts
due to them its conductivity is around 14-15 micro.mhos. 7<
pH <10, so it is further passed through Mixed Bed Deioniser, as
shown below. The mixed bed mixture of Cation and Anion resins
form infinite numbers of demineralising stages through which DM
water passing and thus removing the traces of minerals. By this
method demineralised water of extremely pure quality is
achieved.

Mix bed deioniser

 On discharging, it is charged with 100kg injection of each Hcl
and NaOH.

Water from sand

filters

Cation Anion Degasser

Exchang Exchang
er er

DM Water Mix bed

Storage deioniser
Tank

GNDTP has 2 units of DM Plant, each having capacity

of 40 tonns/hr

DM water storage tank have capacity of 2456m 3

Max running hrs 5(one unit)

Charging Hcl(400kg in cation exchanger)

NaOH (200kg in anion exchanger)

Hcl and NaOH (100kg each in mixed bed)

 Treated water has pH 6.8-7.2 , conductivity < 1
micro.mhos

Hcl charging tank connected with cation

exchanger
 NaOH charging tank connected with anion
exchanger

Coal Testing

Preparation of coal sample

360Kg of Raw coal

Feed size -
Jaw
up to 300mm

Capacity
Crusher - I
20mT/hr

Product size
50mm
 1 2
Conning &
Quartering
Rejected
4 3

Coning and quartering - in this method, we divide the

total amount of coal in 4 equal parts as shown, then we
ignore the 1st & 3rd part. After taking 2nd & 4th part together
(total mass 180Kg) we again use above method to take
another half of earlier collected mass X another half of it,
but now we ignore 2nd and 3rd part and take 1st and 4th part
and get a mass of 90kg.
 Jaw crusher
-I

With the output of jaw crusher I, we do coning & quartering

2 times and hence we get sample of 90Kg.

Coal product produced by this jaw crusher is of size of

50mm.

This 90kg of coal is further crushed in Jaw Crusher II, which

having the capacity of 1 mT/hr

90Kg coal

(size-
50mm)
 Jaw Crusher
II
Feed size 50mm

Capacity 1mT/hr

Product Size-

Two times
conning &
quartering

22.5Kg Coal sample of size

12.5mm

22.5Kg Coal sample of size

12.5mm
 Jaw Crusher -
III

Feed size
12.5mm

Product Size

One time
conning &
quartering

11Kg sample of coal of

size 6mm

11Kg sample of coal of

size 6mm
 Jaw Crusher -
IV

Feed Size - 6mm

Product Size
3mm

Conning &
Quartering
two times 2Kg sample of coal having
size of 3mm

2Kg sample of coal having

size of 3mm
 Grinder

Feed Size
3mm

Product Size
-212microns.

Coal powder
having size of
212microns

Now coal sample of mass 2kg having size of

212microns is sent to chemical department for
testing.
 Coal used is Bituminous having following specifications

Carbon = (60-70) %

Ash = (30-40) %

Moisture < (2) %

Calorific Value = (3500-4500) Kcal/Kg

Coal testing is done to check the grading of the coal.

We check the moisture, ash and volatile content of the coal.

Moisture Content Test

1gm sample of
powdered coal is weighed and taken in the silicon dish. Then this
sample is heated in oven at 1100C for 1hr.then sample is taken
out and again weighed. Loss of weight is the water content.

Ash Content Test

 In this test 1gm sample
of powdered coal is weighed and taken in the silicon dish. Then
this sample is heated in oven at 8100c for 1hr.then Sample is
taken out and again weighed. Remaining is the only ash content.

Volatile Matter Test

For this test 1-gram

sample of powdered coal is taken. This sample is taken in a silicon
crucible dish and heated at 900C for 7 minutes. Then the
remaining amount of sample is noted and the losses are noted.

Volatile metals are Hg and NH3

Conclusion
 Spending my six months of training in Guru Nanak Dev
Thermal Plant, 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 coal handling plant, Boiler section,
Turbine section, De-mineralized water plant, Ash handling plant
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, turbine, compressors, condenser 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
steam turbine, their manufacture, their capacity, their angle of
blades and their manufacturing. The training that I had undergone
in this industry will definitely help me to apply theoretical
knowledge to the practical situation with confidence.