Thermal Power Plant Training File

4 Months Industrial Training Report Page | 1/69
TRAINING REPORT ON
4MONTHS INDUSTRIAL TRAINING

TAKEN AT:
GURU NANAK DEV THERMAL PLANT,
BATHINDA
Submitted in partial fulfillment of the requirements for the award of degree
of BACHELOR OF TECHNOLOGY in MECHANICAL ENGINEERING from:
GZS Campus College of Engineering & Technology,
Bathinda
Submitted to:
Dr. Balwinder Singh Sidhu Submitted By:
HOD Mechanical Engg. Deptt. Abhishek Kumar Yadav
GZSCCET, Bathinda
TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................... 6
CERTIFICATE .......................................................................................................................... 7
ACKNOWLEGMENT .............................................................................................................. 8
1. WHAT IS A THERMAL POWER PLANT .......................................................................... 9
1.1 Concept of Thermal Power Station ................................................................................ 10
1.2 General Layout of Thermal Power Plant ....................................................................... 11
1.2.1 Coal and ash circuit ................................................................................................. 11
1.2.2 Air and gas circuit ................................................................................................... 12
1.2.3 Feed water and steam circuit................................................................................... 12
1.2.4 Cooling water circuit............................................................................................... 12
2. HISTORY OF THERMAL POWER PLANTS ................................................................... 13
3. INTRODUCTION TO GNDTP ........................................................................................... 14
4. BRIEF HISTORY OF PLANT ............................................................................................ 15
5. SITE SELECTION .............................................................................................................. 16
6. CONTRIBUTION OF PLANT............................................................................................ 17
7. PLANT AT A GLANCE ..................................................................................................... 18
8. PLANT SALIENT FEATURES .......................................................................................... 20
8.1 Project Area ................................................................................................................... 20
8.2 Boiler.............................................................................................................................. 20
8.3 Steam Turbine ................................................................................................................ 20
8.4 Generator........................................................................................................................ 21
8.5 Boiler Feed Pumps ......................................................................................................... 21
8.6 Circulating Water Pumps ............................................................................................... 21
8.7 Cooling Towers .............................................................................................................. 22
8.8 Coal Pulverising Mills ................................................................................................... 22
8.9 Rating Of 6.6 kv Auxilliary Motors ............................................................................... 22
GZSCCET, Bathinda
9. WORKING PRINCIPLE OF THERMAL POWER PLANT .............................................. 23
10. WORKING OF THERMAL PLANT ................................................................................ 27
11. BOILER ............................................................................................................................. 29
11.1 Introduction .................................................................................................................. 29
11.2 Classification of Boilers ............................................................................................... 30
11.2.1 Horizontal, Vertical or Inclined ............................................................................ 30
11.2.2 Fire Tube And Water Tube ................................................................................... 30
11.2.3 Externally Fired And Internally Fired................................................................... 31
11.2.4 Forced Circulation And Natural Circulation......................................................... 32
11.2.5 High Pressure And Low Pressure Boiler .............................................................. 32
11.2.6 Single Tube And Multi-Tube Boiler ..................................................................... 33
11.3 Selection of a Boiler..................................................................................................... 33
11.4 Performance of Boiler .................................................................................................. 33
12. BOILER MOUNTINGS .................................................................................................... 34
12.1 Different types of Boiler Mountings ............................................................................ 34
12.1.1 Safety Valve .......................................................................................................... 34
12.1.2 Water Level Indicator ........................................................................................... 35
12.1.3 Pressure Gauge...................................................................................................... 35
12.1.4 Fusible Plug .......................................................................................................... 35
12.1.5 Feed Check Valve ................................................................................................. 36
12.1.6 Blow-Off Cock...................................................................................................... 36
12.1.7 Steam Stop Valve .................................................................................................. 37
13. BOILER ACCESSORIES ................................................................................................. 38
13.1 Economisers ................................................................................................................. 38
13.1.1 Design Requirement for an Economiser ............................................................... 39
13.1.2 Types of Economisers ........................................................................................... 39
13.1.3 Advantages of Economiser ................................................................................... 40
GZSCCET, Bathinda
13.2 Air Preheater ................................................................................................................ 41
13.3 Superheater .................................................................................................................. 43
13.3.1 Types of Superheater ............................................................................................ 43
13.4 Steam Separator ........................................................................................................... 44
14. STEAM TURBINE ............................................................................................................ 45
14.1 Compounding of Steam Turbine .................................................................................. 46
14.1.1 Velocity Compounding ......................................................................................... 46
14.1.2 Pressure Compounding ......................................................................................... 46
14.1.3 Pressure and Velocity Compounding.................................................................... 47
14.1.4 Advantages and Disadvantages of Velocity Compounding.................................. 48
14.2 Losses in Steam Turbine .............................................................................................. 48
14.3 Governing of Steam Turbine ....................................................................................... 49
14.3.1 Throttle Governing................................................................................................ 49
14.3.2 Nozzle Control Governing .................................................................................... 50
14.3.3 By-Pass Governing ............................................................................................... 50
14.4 Turbine Troubles .......................................................................................................... 51
14.5 Blade Materials for Turbines ....................................................................................... 51
15. ALTERNATOR ................................................................................................................. 52
15.1 Theory of Operation ..................................................................................................... 52
15.2 Alternator Protection .................................................................................................... 53
15.2.1 Over Current Protection ........................................................................................ 53
15.2.2 Reverse Power Protection ..................................................................................... 54
16. STEAM CONDENSER ..................................................................................................... 55
16.1 Advantages of Condenser ............................................................................................ 55
16.2 Corrosion and Scale Formation in Condenser Tubes and Their Prevention ................ 56
16.3 Material for Steam Condenser ..................................................................................... 57
17. COOLING WATER SYSTEM.......................................................................................... 58
GZSCCET, Bathinda
17.1 Classification of Cooling Tower .................................................................................. 58
17.1.1 Natural Draught Cooling Tower ........................................................................... 59
17.1.2 Mechanical Draught Cooling Tower .................................................................... 59
17.2 Maintenance of Cooling Tower ................................................................................... 61
18. GENERAL DESCRIPTION .............................................................................................. 62
18.1 Boiler Feed Pump ........................................................................................................ 62
18.2 Water Treatment Plant ................................................................................................. 63
18.3 Coal Mill ...................................................................................................................... 63
18.4 Induced Draught Fan.................................................................................................... 63
18.5 Control Room............................................................................................................... 63
18.6 Wagon Tippler ............................................................................................................. 63
18.7 Crusher House .............................................................................................................. 64
18.8 Cooling Towers ............................................................................................................ 64
18.9 Boiler............................................................................................................................ 64
18.10 Boiler Chimney .......................................................................................................... 64
18.11 Circulating Water Pump ............................................................................................ 64
19. COAL MILLING PLANT ................................................................................................. 65
19.1 Coal Mill ...................................................................................................................... 65
19.1.1 Ball Mills:- ............................................................................................................ 65
19.1.2 Bowl Mills:- .......................................................................................................... 66
19.2 Wagon Tippler ............................................................................................................. 66
19.3 Crusher House .............................................................................................................. 66
20. BOILER SECTION ........................................................................................................... 67
21. BIBLIOGRAPHY .............................................................................................................. 69
GZSCCET, Bathinda
INTRODUCTION
According to the syllabus and requirements of Punjab Technical University, all the B. Tech.
students of mechanical engineering have to undergo six months industrial training. Industrial
Training aims at exposing the students to field practices, size and scale of operation and work
culture at work-stations. For this purpose, in the seventh semester the students go for 6 months
training comprising of 4 months industrial training and 2 months software training. Each
student is supposed to study the material and technology used at site and prepares a detailed
report of the observation recorded by him/her. These students should be supervised and guided
by respective staff members and workers of the industry. I decided to undergo 4months
industrial training at Guru Nanak Dev Thermal Plant, Bathinda. I joined Guru Nanak Dev
Thermal Plant, Bathinda for the said training on 05/06/2017 and completed my training on
30/09/2017.
GZSCCET, Bathinda
CERTIFICATE
GZSCCET, Bathinda
ACKNOWLEGMENT
It is a great pleasure to present this report of summer training in Guru Nanak Dev Thermal
Plant, Bathinda for partial fulfillment of B.Tech in Mechanical Engineering from GZSCCET
Bathinda affiliated to Punjab Technical University. I am highly indebted to Er. Rashim Gera,
Training Head for providing me this wonderful opportunity of doing training at Guru Nanak
Dev Thermal Plant, Bathinda. I am grateful to her for providing me with an enthusiastic
learning environment and helped me sharpen my technical skills. It was wonderful to work in
real environment which dealt with implementation of technology in productive work for
national development. At the outset, I would like to express my immense gratitude to all the
staff of thermal power plant guiding me right from the inception till the successful completion
of the training. I am falling short of words for expressing my feelings of gratitude towards them
for extending their valuable guidance and above all, the moral support they had provided me
with all stages of this training. I would also like to thank all my friends and group members for
their help and cooperation throughout the training.
I am also grateful to Dr. Balwinder Singh Sidhu (H.O.D. Mechanical Engineering), Dr.
Kamaljit Singh Boparai (Training Incharge), Er. Mandeep Singh and the faculty members
of Mechanical Engineering Department for constantly guiding me in the right direction during
the entire course.
Name: Abhishek Kumar Yadav
GZSCCET, Bathinda
1. WHAT IS A THERMAL POWER PLANT

A thermal power plant is an industrial facility for the generation of electric power. It is also
termed as energy centre because it more accurately describes what the plants do, which is the
conversion of other forms of energy like chemical energy, heat energy into electrical energy.
Energy exists in various forms i.e. mechanical, thermal, electrical etc... One form of energy
can be converted into other by the use of suitable arrangements. Out of all these forms of
energy, electrical energy is preferred due to the following advantages:-
 Can be easily transported from one place to another.

 Losses in transport are minimum.
 Can be easily subdivided.
 Economical in use.
 Easily converted into other forms of energy.
Power is primarily associated with mechanical work and electrical energy. Therefore,
power can be defined as the rate of flow of energy and can state that a power plant is a
unit for production and delivery of a flow of mechanical and electrical energy. In
common sages, a machine or assemblage of equipments that produce and delivers a flow
of mechanical or electrical energy is power plant.
A thermal power station is a power plant in which the prime mover is steam driven.
Water is heated, converted into steam and spins a steam turbine which drives an electrical
generator. After it passes through the turbine, the steam is condensed in a condenser and
recycled to where it was heated; this is known as Rankine Cycle. The greatest variation in
the design of thermal power station is due to the different fossil fuel resources generally
used to heat the water. Certain thermal power plants are also designed to produce heat
energy for industrial purposes district heating or desalination of water, in addition to
generating electrical power. Globally, fossil fuelled thermal power plant produce a large
part of man-made CO2 emission to the atmosphere, and efforts to reduce these are many,
varied and widespread.
Commercial electric utility power stations are most usually constructed on a very large
scale and designed for continuous operation. Electric power plants typically use three
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phase or individual phase electric generators to produce Alternating Current (AC) electric
power at a frequency of 50Hz (hertz, which is an AC sine wave per second).
1.1 Concept of Thermal Power Station

Thermal power plant converts energy rich fuel into electricity and heat. Possible fuels include
coal, natural gas, petroleum products, agricultural waste and domestic waste. Other sources of
fuel include landfill gas and bio gases. In some plants renewal fuels such as biogas are co-fired
with coal.
Coal and lignite accounted for about 57% of India’s installed capacity. However, wind energy
depends upon wind speed, and hydropower energy on water level, thermal power plant
accounts for over 65% of India’s generated electricity, India’s electricity sector consumes about
80% of the coal product in the county.
India expects that its projected rapid growth in electricity generation over the next couple of
decades is expected to be largely met by thermal power plant.
FUEL MW %
Total Thermal 119040.98 65.16
coal 100098.38 54.79
gas 17742.85 9.71
oil 1199.75 0.65
Hydro (renewable) 38706.40 21.18
Nuclear 4780.00 2.61
Other Renewable Energies 20162.24 11.03
Total 182689.62 100
Nuclear Other
renewables
Hydro
Renewable Total
Thermal
Figure 1 Different sources of fuel for power plants
GZSCCET, Bathinda
1.2 General Layout of Thermal Power Plant

The general layout of a thermal power plant consists of mainly four circuits. The four main
circuits are:
i. Coal and ash circuit.

ii. Air and gas circuit.
iii. Feed water and steam flow circuit.
iv. Cooling water circuit.
Figure 2 Layout of thermal power plant
A thermal power station using steam as working fluid basically works on the Rankine cycle.
Steam is generated in a boiler, expanded in the prime mover and condensed in condenser and
fed into the boiler again with the help of pump. However, in actual practice, there are numerous
modifications and improvements in the cycle with the aim of affecting heat economy and to
increase the thermal efficiency of the plant.
1.2.1 Coal and ash circuit
In this circuit, the coal from the storage is fed to the boiler through coal handling equipment
for the generation of steam. Ash produced due to combustion of coal is removed to ash storage
through ash-handling system.
GZSCCET, Bathinda
1.2.2 Air and gas circuit

Air is supplied to the combustion chamber of the boiler either through F.D or I.D fan or by
using both. The dust from the air is removed before supplying to the combustion chamber. The
exhaust gases carrying sufficient quantity of heat and ash are passed through the air-heater
where the exhaust heat of the gases is given to the air and then it is passed through the dust
collectors where most of the dust is removed before exhausting the gases to the atmosphere
through the chimney.
1.2.3 Feed water and steam circuit

The steam generated in the boiler is fed to the steam prime mover to develop the power. The
steam coming out of prime mover is condensed in the condenser and then fed to the boiler with
the help of pump. The condensate is heated in the feed-heaters using the steam tapped from
different points of the turbine. The feed heaters may be of mixed type or indirect heating type.
Some of the steam and water is lost passing through different components of the system;
therefore, feed water is supplied from external source to compensate this loss. The feed water
supplied from external source is passed through the purifying plant to reduce the dissolved salts
to an acceptable level. The purification is necessary to avoid the scaling of the boiler tubes.
1.2.4 Cooling water circuit

The quantity of cooling water required to condensate the steam is considerably large and it is
taken either from lake, river or sea. The cooling water is taken from the upper side of the river;
it is passed through the condenser and discharged to the lower side of the river. Such system
of cooling water supply is possible if adequate cooling water is available throughout the year.
This system is known as open system. When adequate water is not available, then the water
coming out from the condenser is either cooled in the cooling pond or cooling tower. The
cooling is affected by partly evaporating the water. This evaporative loss is nearly 2 to 5% of
the cooling water circulated in the system. To compensate the evaporative loss, the water from
the river is continuously supplied. When the cooling water coming out of the condenser is
cooled again and supplied to the condenser, then the system is known as closed system. When
the water coming out of the condenser is discharged to river downward side directly, the system
is known as open system.
GZSCCET, Bathinda
2. HISTORY OF THERMAL POWER PLANTS

The initially developed reciprocating steam engine has been used to produce mechanical power
since the 18th century, with notable improvements being made by James Watt. When the first
commercially developed central electrical power stations were established in 1882 at Pearl
Street in New York and Holborn viaduct power station in London, reciprocating steam engines
were used. The development of steam turbine in 1884 provided large and more efficient
machine designs for central generating stations. By 1892 the turbine was considered a better
alternative to reciprocating engines; turbines offered higher speeds, more compact machinery,
and stable speed regulation allowing for parallel synchronous operation of generators on a
common bus. After about 1905, turbines entirely replaced reciprocating engines in large central
power stations.
The largest reciprocating steam engine-generator sets ever built were completed in 1901 for
the Manhattan Elevated Railway. Each of seventeen units weighed about 500tonnes and was
rated 6000kilowatts; a contemporary turbine set of similar rating would have weighed about
20% as much.
GZSCCET, Bathinda
3. INTRODUCTION TO GNDTP
Guru Nanak Dev Thermal Power Plant (G.N.D.T.P) is a coal-based plant. The requirement of
coal for four units based on specific fuel consumption of 0.60 kg / kWh. The conveying and
crushing system will have the same capacity as that of the unloading system. The coal comes
in as large pieces. This coal is fed to primary crushers, which reduce the size of coal pieces
from 400mm to 150mm. Then the coal is sent to secondary crusher through forward conveyors
where it is crushed from 150mm to 200mm as required at the mills. Then the coal is sent to
boilers with the help of primary fans. The coal is burnt in the boiler. Boiler includes the pipes
carrying water through them; heat produced from the combustion of coal is used to convert
water in pipes into steam. This steam generated is used to run the turbine. When turbine rotates,
the shaft of generator, which is mechanically coupled to the shaft of turbine, gets rotated so,
three phase electric supply is produced.
The basic requirements are:-
 Fuel (coal)
 Boiler
 Steam turbine
 Generator
 Ash handling system
 Unit auxiliaries
GZSCCET, Bathinda
4. BRIEF HISTORY OF PLANT

Due to high rate of increasing population day by day, widening gap between power demand
and its availability was one of the basic reason for envisaging the G.N.D.T.P. for the state of
Punjab. The other factors favouring the installation of the thermal power station were low initial
cost and comparatively less gestation period as compared to hydroelectric generating stations.
The foundation stone of G.N.D.T.P. at Bathinda was laid on 19th November 1969, the
auspicious occasion of 500th birth anniversary of great Guru Nanak Dev Ji.
The historic town of Bathinda was selected for this first and prestigious thermal project of the
state due to its good railway connections for fast transportations of coal, availability of canal
water and proximity to load center.
The total installed capacity of the power station 440MW with four units of 110MW each. The
first unit of the plant was commissioned in September, 1974. Subsequently second, third and
fourth units started generation in September 1975, March 1978, and January 1979 respectively.
The power available from this plant gives spin to the wheels of industry and agricultural
pumping sets.
GZSCCET, Bathinda
5. SITE SELECTION
The selection of site for Thermal Power Plant is more difficult compared to Hydro Power Plant
as it involves number of factors to be considered for i.e. economic justification. The following
consideration should be examined in detail before selection of the site for the Plant. The
location for plant should be made with full consideration not only of the trends in the
development and location but also the availability and location of the cheapest source of
primary energy:-
 Availability of fuel
 Ash disposal facilities
 Space requirement
 Nature of land
 Availability of labour
 Transport facilities
 Public society problems
 Development of Backward Area
GZSCCET, Bathinda
6. CONTRIBUTION OF PLANT
Guru Nanak Dev Thermal Plant Bathinda in addition to indirect contribution in various facts
of state economy, is also responsible for:-
 Narrowing the gap between power demand and power availability of the state.
 Providing employment potentials to thousands of workers.
 Covering the backward surrounding area into fully developed Industrial Township.
 Providing additional relief to agricultural pumping sets to meet the irrigation needs for
enhancing the agriculture production.
 Reliability and improvement in continuity of supply and system voltage.
 Achieving cent percent rural electrification of the state.
GZSCCET, Bathinda
7. PLANT AT A GLANCE
1) Location Bathinda (Punjab)
2) Main Features Highest Generation achievement in 2007-08 (3008MU)
Highest PLF in March 1987 (88.14%)
Lowest Ever yearly aux. consumption 2002-03 (9.32%
without T&E Losses)
Lowest DM Water make up in 2013-14 (1.91%)
Lowest Oil Consumption in 2013-14 (1.34 ml/Kwh)
3) No. of Power House ONE
4) No. of Unit FOUR
5) Total generating capacity 2 x 110 MW+2×120= 460 MW (w.e.f 27.09.2014)
6) Source of water supply Canal water
7) Fuel Used Primary Fuel: Bituminous coal with calorific value
3500-4500 kcal/kg
Secondary Fuel: Fuel oil/L.D.O./HPS/FO with calorific
value of 9,000 to 10,000 K.Cal / liter.
8) Turbine ( Stage-1) Three casing type impulse turbines 110 MW capacity
with 3000 rpm, 29 stages with exhaust pressure 0.08
kg/sq. cm
Turbine (Stage-2) Three casing type Reaction turbines 120 MW capacity
with 3000 rpm, HP-26 stages, MP-16 stages and LP-6
stages double flow with exhaust pressure 0.12 kg/sq. cm
9) Generator (Satge-1) BHEL make three phase synchronous type 110
MW,11000 V with H2 cooling and Static exciter.
Generator (Satge-2) BHEL make three phase synchronous type 120
MW,11000 V with H2 cooling and Static exciter.
10) Commissioning U-1 = 22.9.74 U-2 = 19.9.75
U-3 = 29.3.78 U-4 = 31.1.79
Date of commissioning after R&M :
GZSCCET, Bathinda
U-1 = 31.05.2007, U-2 = 19.01.2006,

U-3 = 07.12.2012, U-4 = 27.09.2014
11) Cost of Project Original Cost: Rs. 115 Crores
R&M Cost for U#1 & U#2= Rs. 229 Crore
R&M Cost for U#3 & U#4= Rs. 465 Crore
GZSCCET, Bathinda
8. PLANT SALIENT FEATURES

8.1 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 (approx.)
Station Capacity Four units of 110MW each
8.2 Boiler
Manufactures Bharat Heavy Electricals Limited (BHEL)
Maximum Continuous Rating (M.C.R) 375T/hr
Super heater Outlet Pressure 139kg/cm2
Reheater Outlet Pressure 33.8kg/cm2
Final Superheater/ Reheater Temperature 540°C
Feed Water Temperature 240°C
Efficiency 86%
Coal Consumption Per Day Per Unit 1400 tones (Approximate)
8.3 Steam Turbine

Manufacturers Bharat Heavy Electricals Limited (BHEL)
Rated output 110 MW
Rated speed 3000 rpm
GZSCCET, Bathinda
Number of cylinders three
Rated pressure 130 kg/cm2
Rated temperature 535°C
Condenser vacuum 0.9 kg/cm2
8.4 Generator
Manufacturers Bharat Heavy Electricals Limited (BHEL)
Rated output
(Unit- 1 & 2) 125000 KVA
(Unit -3 & 4) 137000 KVA
Generator voltage 11000 volts
Rated phase current

(unit -1 & 2) 6560 Amps.
(unit -3 8c 4) 7220 Amps.
Generator cooling Hydrogen
8.5 Boiler Feed Pumps

Number per unit two of 100% duty each
Type centrifugal
Rated discharge 445 T/hr.
Discharge head 1960 MWC (meters of water column)
Speed 4500 rpm
8.6 Circulating Water Pumps

Numbers for two units five of 50% duty each
Type mixed flow
Rated discharge 8600 T/hr
Discharge head 24 MWC (meters of water column)
GZSCCET, Bathinda
8.7 Cooling Towers

Numbers Four
Water cooled 18000 T/hr.
Cooling range 10°C
Height 120/12metres
8.8 Coal Pulverising Mills

Numbers three per unit
Type drum-ball
Rated output 27 T/hr.
Coal bunkers 16 per unit
8.9 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
GZSCCET, Bathinda
9. WORKING PRINCIPLE OF THERMAL POWER

PLANT
A thermal power station works on the basic principle that heat liberated by burning fuel is
converted into mechanical work by means of a suitable working fluid. The mechanical work is
converted into electric energy by the help of generators.
Steam is generated in the boiler of the thermal power plant using the heat of the fuel burned in
the combustion chamber. The steam generated is passed through steam turbine where part of
its thermal energy is converted into mechanical energy which is further used for generating
electric power. The steam coming out of the steam-turbine is condensed in the condenser and
the condensate is supplied back to the boiler with the help of the feed pump and the cycle is
repeated.
The function of the boiler is to generate the steam. The function of the condenser is to
condensate the steam coming out of steam turbine at low pressure. The function of the steam
turbine is to convert part of heat energy of steam into mechanical energy. The function of pump
is to raise the pressure of the condensate from the condenser pressure (0.015 bars) to boiler
pressure (8 bars). The other components like economiser, superheater are used in the primary
circuit to increase the overall efficiency of the thermal power plant.
Figure 3 Rankine Cycle
The working fluid in a Rankine cycle follows a closed loop and is reused constantly. The water
vapour with condensed droplets often seen billowing from power stations is created by the
cooling systems (not directly from the closed-loop Rankine power cycle) and represents the
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means for (low temperature) waste heat to exit the system, allowing for the addition of (higher
temperature) heat that can then be converted to useful work. This 'exhaust' heat is represented
by the "Qout" flowing out of the lower side of the cycle.By condensing the working steam
vapour to a liquid the pressure at the turbine outlet is lowered and the energy required by the
feed pump consumes only 1% to 3% of the turbine output power and these factors contribute
to a higher efficiency for the cycle.
Figure 4 T-S Diagram of a Rankine Cycle
The different processes of the Rankine cycle are described below:
1. The point ‘d’ represents the water at condenser pressure p2 and corresponding saturation
temperature T2. The process ‘de’ represents the adiabatic compression of water by the
pump from condenser pressure to boiler pressure. There is slight rise in temperature of
water during the compression process.
2. During the process ‘ea’ and ‘ab’, heat is supplied by the boiler to the water to convert
into steam. The process ‘ea’ represents the supply of heat at constant pressure till the
saturation temperature of water is reached corresponding to boiler pressure. The process
‘ab’ represents the addition of heat to the water at constant pressure till the water
completely converts into steam. The final condition of steam may be wet, dry saturated
or super heated depending upon the quantity of heat supplied by the boiler.
GZSCCET, Bathinda
3. The process ‘bc’ represents the isentropic expansion of steam in the prime mover.
During this expansion process, external work is developed and the pressure of steam
falls from p1 to p2 and its temperature will be T2.
4. The process ‘cd’ represents the condensation of steam coming out from the prime
mover in the condenser. During the condensation of steam, the pressure is constant and
there is only change of phase from steam to water as the latent heat of steam is carried
by circulating water in the condenser. Again the process ‘de’ represents the adiabatic
compression of water by the pump from the pressure p2 to p1 and the cycle is repeated.
Let
hb = enthalpy of steam per kg at point ‘b’
hc = enthalpy of steam per kg at point ‘c’
vw = specific volume of water at point 1 or 2 as there is much change in specific volume during
this process
hfe = enthalpy of water per kg at point ‘e’
hfa = enthalpy of water per kg at point ‘a’
hfd = enthalpy of water per kg at point ‘d’
Total heat supplied by the boiler per kg of steam generated
= hb - hfe
= hb – (hfd + wp)
Where wp is the work done by the pump per kg of water supplied.
Work done per kg of steam in the prime mover
= hb - hc
Work done by the pump per kg of water supplied to the boiler
wp = [vf2 (p1 – p2)] J/kg where p is in N/m2
where vf2 is the specific volume of saturated water at pressure p2.
GZSCCET, Bathinda
Net work available per kg of water
= (hb – hc) – vfa (p1 – p2)

1000
= (hb – hc) – wp
The Rankine efficiency of the cycle is given by
ɳr= Net work available

Heat supplied
= [(hb – hc) – wp] / [hb – (hfd + wp)]
The pump work is always neglected for all practical purpose as it is very small compared with
other heat quantities.
ɳr = (h3 - h4) / (h3 - hf4) as wp is zero.
GZSCCET, Bathinda
10. WORKING OF THERMAL PLANT

Coal received from collieries in the rail wagon is mechanically unloaded by Wagon Tippler
and carried by belt Conveyor System to 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
of 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 (MP) 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 (LPH) from the deaerator, a hot
water storage tank. The boiler feed pump discharge feed water to boiler at the economizer by
GZSCCET, Bathinda
the hot flue gases leaving the boiler, before entering the boiler drum to which the water walls
and superheater 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 though 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.
GZSCCET, Bathinda
11. BOILER
11.1 Introduction
Steam is mainly required for power generation, process heating and space heating purposes.
The capacity of the boilers used for power generation is considerably large compared with
other boilers.
Due to the requirement of high efficiency, the steam for power generation is produced at high
pressures and in very large quantities. They are very large in size and are of individual design
depending on the type of fuel used.
A steam generator popularly known as boiler is a closed vessel made of high quality steel in
which steam is generated from water by the application of heat. The water receives heat from
the hot gases through the heating surface of the boiler. The hot gases are formed by burning
fuel, may be coal, oil or gas. Heating surface of the boiler is that part of the boiler which is
exposed to hot gases on one side and water or steam on the other side. The steam which is
collected over the water surface is taken from the boiler through super heater and then suitable
pipes to turbine. Usually boilers are coal or oil fired.
According to American Society of Mechanical Engineers (A.S.M.E.) a ‘steam generating unit’

is defined as: “A combination of apparatus for producing, furnishing or recovering heat
together with the apparatus for transferring the heat so made available to the fluid being heated
and vaporised”.
The steam generated is employed for the following purposes:
i. For generating power in steam engines or steam turbines.

ii. In the textile industries for sizing and bleaching etc. and many other industries like
sugar mills; chemical industries.
iii. For heating the building in cold weather and for producing hot water for hot water
supply.
The primary requirements of boiler are:
a) The water must be contained safely.

b) The steam must be safely delivered in desired condition.
GZSCCET, Bathinda
11.2 Classification of Boilers

The boilers may be classified as follows:
11.2.1 Horizontal, Vertical or Inclined

If the axis of the boiler is horizontal, the boiler is called as horizontal, if the axis is vertical, it
is called vertical boiler and of the axis is inclined it is known as inclined boiler. The parts of a
horizontal boiler can be inspected and repaired easily but it occupies more spaces. The vertical
boiler occupies less floor area.
Figure 5 Horizontal Boiler
11.2.2 Fire Tube And Water Tube

In the fire tube boilers, the hot gases are inside the tubes and the water surrounds the tubes.
Examples: Cochran, Lancashire and Locomotive boilers.
Figure 6 Fire tube Boiler
In the water tube boilers, the water is inside the tube and hot gases surround them. Examples:
Babcock and Wilcox, Stirling boiler etc.
GZSCCET, Bathinda
Figure 7 Water Tube Boiler
11.2.3 Externally Fired And Internally Fired

The boiler is known as externally fired if the fire is outside the boiler shell. Examples: Babcock
and Wilcox, Stirling boiler.
Figure 8 Babcock and Wilcox Boiler
GZSCCET, Bathinda
In case of internally fired boilers, the furnace is located inside the boiler shell. Example:
Cochran, Lancashire boiler etc.
Figure 9 Lancashire Boiler
11.2.4 Forced Circulation And Natural Circulation

In forced circulation type boilers, the circulation of water is done by a forced pump. Examples:
Velox, Lamont, Benson boiler etc.
In natural circulation type boilers, circulation of water in the boiler takes place due to natural
convention currents produced by the application of heat. Examples: Lancashire, Babcock and
Wilcox boiler etc.
Figure 10 Forced Circulation and Natural Circulation Boiler
11.2.5 High Pressure And Low Pressure Boiler

The boiler which produce steam at a pressure of 80 bar and above are called high pressure
boiler. Examples: Babcock and Wilcox, Velox, Lamont, Benson boilers.
The boilers which can produce steam at a pressure below 80 bars are called low pressure
boilers. Examples: Cochran, Cornish, Lancashire and locomotive boilers.
GZSCCET, Bathinda
11.2.6 Single Tube And Multi-Tube Boiler

The fire tube boilers are classified as single tube and multi-tube boilers, depending upon
whether the fire tube is one or more than one. The examples of former type are Cornish, simple
vertical boiler and rest of the boilers are multi-tube boilers.
11.3 Selection of a Boiler

The following factors should be considered while selecting a boiler:
 The working pressure and quality of steam required.

 Steam generation rate.
 Floor area available.
 Accessibility for repair and inspection.
 Comparative initial cost.
 The probable load factor.
 The fuel and water available.
 Operating and maintenance cost.
11.4 Performance of Boiler

Evaporative Capacity
Performance of boiler is expressed in terms of evaporative capacity which is defined as the

amount of water evaporated or steam produced in kg per hour.
Boiler Efficiency
Boiler efficiency is the ratio of heat actually utilised in generation of steam to the heat supplied
by the fuel in the same period.
i.e., boiler efficiency = [ma (h - hf1)]/C
Where, ma = mass of water actually evaporated into steam per kg of fuel at the working
pressure,
h = enthalpy of steam per kg under the generating condition,
hf1 = specific enthalpy of water at a given feed temperature, and
C = calorific value of fuel in kJ/kg.
If the boiler, economiser, and superheater are considered as a single unit, then the boiler
efficiency is termed as overall efficiency of the boiler plant.
GZSCCET, Bathinda
12. BOILER MOUNTINGS

Different fittings and devices necessary for the operation and safety of a boiler are known as
boiler mountings. The safety valve, water level indicator, and the fusible plug are the devices
used for safety operation of the boiler. The pressure gauge, feed check valve, blow-off cock
and steam stop valve fall under the category of fittings and these are essential for the operation
of the boiler.
12.1 Different types of Boiler Mountings
12.1.1 Safety Valve

When there is a sudden drop in steam requirements, the steam pressure in the boiler will
increase. The main function of a safety valve is to prevent under such a condition, an increase
in the steam pressure in the boiler exceeding a predetermined, maximum pressure for which
the boiler is designed. This is automatically done by opening of the valve and discharging the
steam to the atmosphere as soon as the pressure inside the boiler increases above the
predetermined value. The safety valves are directly placed on the top of the boiler shell.
Spring Loaded type of safety valve is commonly used now-a-days for stationary as well as
mobile boilers. It is loaded with spring instead of weights. The spring is made from a square
steel rod in helical form.
Spring loaded safety valve consists of two valves, each of which is placed over a valve seat
fixed over a branch pipe. The two branch pipes are connected to a common block which is
fixed on the shell of the boiler. The lever has two pivots each of which is placed over each
respective valve. The lever is attached with a spring at its middle which pulls the lever in
downward direction. The lower end of the spring is attached to the back. Thus the vales are
held tight to their sates by the spring force.
These valves are fitted against the spring when the steam pressure is
greater than the working pressure and allows the steam to escape
from the boiler till the pressure in the boiler reaches its working
pressure. The lever has an extension which projects into the driver’s
cabin. The driver can release the pressure if required just by raising
the lever. The lever is connected loosely by a link to the block. This
limits the valve opening and prevents the lever blowing off in case
of spring failure. Figure 11 Safety Valve
GZSCCET, Bathinda
12.1.2 Water Level Indicator

It is an important fitting which indicates water level inside the boiler to the observer. Usually
two water level indicators are fitted in front of the boiler. The water indicator shows the level
or water in the boiler drum and warns the operator if by chance the water level goes below a
fixed mark, so that corrective action may be taken in time to avoid any accident.
12.1.3 Pressure Gauge

A pressure gauge is used to measure the pressure of steam inside the boiler. The commonly
used pressure gauge is known as Bourdon type pressure gauge. It consists of an elastic
metallic type of elliptical cross-section and is bent in the form of circular arc. One end of the
tube is fixed and connected to the steam space of the boiler and other end is connected to a
sector wheel through a link. The sector remains in mesh with a
pinion fixed on a spindle to read the pressure on a dial gauge.
When high pressure steam enters the elliptical tube, the tube
section tries to become circular which causes the other end of
the tube to move outward. The movement of the closed end of
the tube is transmitted and magnified by the link and sector.
Figure 12 Pressure Gauge
The magnitude of the movement is indicated by the pointer on
the dial.
12.1.4 Fusible Plug

The main objective of the fusible plug is to put off the fire in the furnace of the boiler when the
water level in the boiler falls below an unsafe level and thus avoids the explosion which may
take place due to overheating of the tubes and shell. This plug is generally fitted over the crown
of the furnace or over the combustion chamber.
Figure 13 Fusible Plug
GZSCCET, Bathinda
Under normal water level condition in the boiler, this plug is covered with water which keeps
the temperature of the fusible metal below its melting point. But when the water level in the
boiler falls low enough to uncover the plug; the fusible metal between the plug quickly melts
and drops out. The opening so made allows the steam to rush the water into the furnace and
extinguish the fire. The steam rushing out puts out the fire and gives warning that the crown
of the furnace is in danger of being overheated.
12.1.5 Feed Check Valve

The function of the feed check valve is to
allow the supply of water to the boiler at high
pressure continuously and to prevent the back
flow of water from the boiler when pump
pressure is less than boiler pressure or when
pump fails.
It is fitted to the shell slightly below the

normal water level of the boiler. The lift of
the non-return valve is regulated by the end
Figure 14 Feed Check Valve
position of the spindle which is attached
with the hand wheel. The spindle can be moved upward or downward with the help of hand
wheel as the upper portion of the spindle is screwed to a nut.
At normal working condition, the non-return valve is lifted due to the pressure of water from
the pump and the water is fed to the boiler. But when the pump pressure falls below boiler
pressure or if the pump stops, non-return valve is closed automatically due to the pressure of
the steam from the boiler and prevents the escape of water from the boiler.
12.1.6 Blow-Off Cock

The blow-off cock used for dual functions:
 To empty the boiler when necessary for cleaning, repair and inspection.
 To discharge the mud and sediments carried with the feed water and
accumulated at the bottom of the boiler.
GZSCCET, Bathinda
By periodic blow-off, the salt concentration in the boiler is also reduced. Even with a small
amount of dissolved salt, over a period of time, due to the evaporation of water, the salt
accumulates in the boiler, raising the salt concentration.
It is fitted to the lowest part of the boiler

either directly with the boiler shell or to a
pipe connected with the boiler.
It consists of a conical plug fitted

accurately into a smaller casing. The plug
has a rectangular opening which may be
brought with the line of the passage of the
casing by rotating the plug. This causes
the water to be discharged from the boiler.
The discharging of water may be stopped Figure 15 Blow-Off Cock
by rotating the plug again.
The blow-off cock should be operated only when the boiler is on if the sediments are to be
removed. This is because; the sediments are forced out quickly due to the high steam pressure
in the boiler.
12.1.7 Steam Stop Valve

It is the largest valve on the steam boiler and usually fitted to the highest part of the boiler shell.
The function of the stop valve is to regulate the flow of steam from the boiler to the turbine as
per requirement and shut off the steam flow when not required.
The main body is made of cast steel. The valve, valve seat and
the nut through which the valve spindle works, are made of
brass for smooth working. The spindle is passed through a
gland to prevent the leakage of steam. The spindle is rotated by
means of hand wheel. Due to the rotation of hand wheel, the
valve may move up or down and it may close or open the
passage fully or partially for the flow of the steam.
Figure 16 Steam Stop Valve
GZSCCET, Bathinda
13. BOILER ACCESSORIES

Accessories are the auxiliary plants required for steam boilers for their proper operation and
for the increase of their efficiency. Water feeding equipments, air-preheater, economisers and
super heaters are some of the essential accessories of the boiler.
In the present age of costly fuel, it has become necessary to conserve the fuel by utilizing the
wasted energy to the atmosphere. This is done in all modern power plants by incorporating
economiser and air preheater. By increasing the temperature of feed water passing through the
economiser using waste heat of gas, the quantity of heat given per kg of steam generated in the
boiler is reduced. Similarly, the temperature of air is also increased by passing through the air
preheater using remaining waste energy of the gases. The preheated air increases the
combustion efficiency in the furnace and reduces the fuel loss. In both equipments, the quantity
of fuel is reduced by extracting the heat from the exhaust gases.
The common equipments used in thermal power plants to increase the thermal efficiency are
economisers, and air pre-heaters. The heat carried with the flue gases is partly recovered in air-
preheater and economiser and reduces the fuel supplied to the boiler. The preheating of air with
gases increases the combustion efficiency and reduces the fuel consumption.
The adoption of one or both equipments depends upon the economic justification. It is also
equally essential to maintain the performance of these equipments by preventing corrosion and
fouling from inside and outside; otherwise the gain from these equipments reduces rapidly with
respect to time. The corrosion is generally prevented by using proper materials for the
equipments and controlling the flue gas temperature to avoid the condensation of corrosive
gases carried by the exhaust gases.
13.1 Economisers
An economiser is a device used for heating the feed water by means of flue gases from boiler.
The economiser usually extracts the waste heat of the chimney gases to preheat the water before
it is fed into the boiler.
A boiler producing between 10 to 100tonnes of steam per hour and operating at 30% or more
loads should be evaluated for possible retrofitting with an economiser. The cost benefits depend
upon the boiler size; type of fuel used and exhausts gas temperature. It has been estimated that
about 1% fuel can cost can be saved for every 6˚C rise in temperature of the boiler feed water.
GZSCCET, Bathinda
Saving upto maximum 20% can be achieved by incorporating economiser where boiler
operates very effectively.
When more heat is available, that can be used in increasing the sensible heat of the feed water
or pass it through an air heater. However, in most economisers, the feed water is not heated
higher than to within 25˚C of the temperature corresponding to the saturation temperature of
steam in the boiler thus preventing steam formation in the economiser.
13.1.1 Design Requirement for an Economiser

The design requirements must satisfy the following conditions:
 The heat transfer surface should be minimum.

 It must be able to extract maximum possible heat from exhaust gases.
 The height of the tube banks should be minimum so the cleaning on load can be done
effectively.
 The gas side pressure loss should be minimum to reduce the running expenses of I.D.
fans.
 There must be uniform water flow to avoid the steam formation in the economiser. The
pressure loss of water side must be also minimum to reduce the running expenses of
the pump.
 There must be connection from steam and water drum to the economiser inlet header,
to permit the free circulation of water around the economiser to prevent the overheating
and boiling during the period when there is no feed-flow during early pressure rising
stages.
13.1.2 Types of Economisers

Basically there are two types of economisers:
i. Plain Tube Economiser- Plain tube types are generally used under natural draught
condition. The tubes are made of cast iron to resist corrosive action of the flue gases
and their ends are pressed into top and bottom headers. An economiser consists of a
group of these cast iron tubes located in the main flue between the boiler and the
chimney. The waste flue gases flow outside the economiser tubes and heat is transferred
to the feed water flowing inside the tubes. The external surfaces of the tubes are
continuously cleaned by soot scrapers moving up and down.
GZSCCET, Bathinda
ii. Gilled Tube Type Economiser- A reduction in economiser size together with increase
in heat transmission can be obtained by casting rectangular gills on the bare tube walls.
Cast iron gilled tube economiser can be used upto 50bar working pressure and such
economisers are indigenously available. At higher pressure steel tubes are used instead
of cast-iron gilled sleeves are shrunk to them.
Corrosion of Economiser and Its Prevention. The corrosion and its prevention are very
important for safe and efficient working of the economiser. Internal and external corrosion are
the primary enemies of an economiser and dissolved O2 and CO2 are the major culprits.
A properly designed deaerator, combined with water treatment plant, virtually eliminates
internal corrosion in the economiser tubes. Deaeration removes 95% dissolved O2 and CO2
from the feed water. Vigorous steam scrubbing with chemical assist should follow deaeration
to ensure complete O2 removal and corrosion control.
CO2 forms carbonic acid (H2CO3) when it dissolves in water. This compound is unstable and
ionizes into H2 ion (H+) and bicarbonate radical (H CO3-). The HCO3- further ionizes to form
the H+ ion and carbonate ion (CO3-). The H2CO3 is the only one that exerts gas pressure;
therefore, CO2 must be removed by deaeration at low pH levels.
NH3 gas forms NH4OH (ammonium hydroxide) upon dissolving in water. NH4OH ionizes to
form NH4+ and OH- ions. Therefore, NH4OH is responsible for exerting gas pressure and it
must be removed by deaeration at higher pH.
The pH value of water passing through the economiser should be maintained between 8 and 9
to reduce its effect of acid. CO2 removal is achieved at low pH and NH3 removal is achieved
at high pH, therefore complete degasification of flow containing combination of two is very
difficult to achieve through deaeration alone.
13.1.3 Advantages of Economiser

There are several indirect advantages obtained by installing an economiser with a boiler plant
as listed below:
a) The feeding of the boiler with water at a temperature near the boiling point reduces the
temperature differences in the boiler, prevents the formation of stagnation pockets of
the cold water and thus reduces greatly the thermal stress created in the pressure part of
the boiler and the boiler and promotes better internal circulation.
GZSCCET, Bathinda
b) When the feed water is not as pure as it should be, the temporary hardness is deposited
on the inside of the economiser tubes and while this necessitates internal cleaning of
the economiser, the evil is not as great as internal cleaning of the boiler.
c) Due to the reduction in the combustion rate of the furnace, the boiler will be more
efficient and the actual fuel saving will be greater than the theoretically calculated.
d) The flow of flue gases over the economiser tubes acts indirectly as a grit arrester and
large portion of the soot and fly-ash is deposited on the tubes and scraped off into the
soot chamber. This reduces the omission of soot and fly-ash.
13.2 Air Preheater

Air preheater, recovers some portion of the waste heat of the flue gases. Air supplied to the
combustion chamber is preheated by using the heat in the waste flue gases. Airs preheater is
placed after the economiser and before the gases enter the chimney.
The heat carried with the flue gases coming out of the economiser is further utilised for
preheating the air before supplying to the combustion chamber. It has been found that an
increase of 20˚C in the air temperature increases the boiler efficiency by 1%.
The air heater is not only considered in terms of boiler efficiency in modern power plants, but
also as a necessary equipment for supply of hot air for drying the coal in pulverised fuel systems
to facilitates grinding and satisfactory combustion of fuel in the furnace.
The use of preheater is much economical when used with pulverised fuel boilers because the
temperature of flue gases going out is sufficiently large and high air temperature is always
desirable for better combustion.
Air heaters are usually installed on steam generators that burn solid fuels but rarely on gas or
oil fired units. By contrast, economisers are specified for most boilers burning liquid or gas or
coal whether or not an air heater is provided.
The principal benefits of preheating the air are:
 Improved combustion.
 Successful use of low grade fuel.
 Increased thermal efficiency.
 Saving in fuel consumption.
 Increased steam generation capacity of the boiler.
GZSCCET, Bathinda
The air preheater are generally divided into two groups as recuperative and regenerative type.
The recuperative heaters continuously transfer the heat from hot gases to cold air. The
regenerative heater alternately gets heated and cooled by hot gases and cold air. Unlike the
recuperative type, the regenerative is discontinuous in action and operates on cycle. In rotary
regenerative type, the cyclic action applies to the heating and cooling of an individual element
of the surface but the flowing steam of air receives heat continuously.
The two recuperative types of heat-exchangers which are commonly used for air-heating are
described below:
a) Tubular Air-Heater- The flue gases

flow through the tubes and air is
passed over the outer surface of the
tubes. The horizontal baffles are
provided to increase time of contact
which will help for higher heat
transfer. The steel tubes 3 to 10 m in
height and 6 to 8 cm in diameter are
commonly used.
b) Plate Type Air-Heater- It consists of
rectangular flat plates spaced from
1.5 to 2.5 cm apart leaving alternate
air and gas passage. This type of air-
Figure 17 Tubular Air-Heater
heater is not used in modern
installation as it is more expensive both as to flat cost and maintenance cost compared
with tubular air-heaters.
Regenerative Heat Exchangers- The transfer of heat from hot gases to cold air is divided into
two stages. In the first stage, the heat of the hot gases flowing through the heat exchanger is
transferred to the packing of the heater and it is accumulated in the packing and the hot gases
are cooled to sufficiently low temperature before exhaust to atmosphere. This stage is referred
to as ‘Heating period’. In the second stage, the cold air is passed through the hot packing where
the heat is accumulated and the heat from the packing is transferred to the cold air. This stage
is known as ‘Cooling period’.
GZSCCET, Bathinda
13.3 Superheater
The function of the super heater in the thermal power plant is to remove the last traces of
moisture (1 to 2%) from the saturated steam coming out of boiler and to increase its temperature
sufficiently above saturation temperature. The superheating raises overall cycle efficiency as
well as avoids too much condensation in the last stages of the turbine which avoids the blade
erosion.
The heat of combustion gases from furnace is utilised for the removal of moisture from steam
and to superheat the steam. Super heaters usually have several tube circuits in parallel with one
or more return bends, connected between headers.
Figure 18 Super Heater
Superheated steam has the following advantages:
 Steam consumption of the turbine is reduced.

 Losses due to condensation in the cylinder and the steam pipe are reduced.
 Erosion of turbine blade is reduced.
 Efficiency of the steam plant is increased.
13.3.1 Types of Superheater

There are two types of super heaters:
1. Convective superheater
2. Radiant superheater
GZSCCET, Bathinda
Convective superheater makes use of heat in flue gases whereas a radiant superheater is placed
in the furnace and a wall tube receives heat from the burning fuels through radiant process. The
radiant type of superheater is generally used where a high amount of superheat temperature is
required.
Heat from the hot gases to the vapour in the superheater is transferred at high temperatures.
Therefore primary section of superheater is arranged in counter flow and secondary section in
parallel flow to reduce the temperature stressing of the tube wall. The metal used for superheat
tubes must have high temperature strength, high creep strength and high resistance to oxidation
as superheater tubes get rougher service than water wall of the modern boilers. Carbon steels
(510˚C) and chromium-molybdenum alloys (650˚C) are commonly used for superheater tubes.
The superheater tubes are subjected to corrosion when they are exposed to oxidising and
reducing conditions alternately. This destroys the protective oxide film and exposes the metal
surface open to further corrosion. The alkali deposits formed also have corrosion effect on steel
depending upon its temperature and composition. Low chromium ferritic steels confer some
corrosion resistance but marked resistance is obtained by the use of austenitic alloys.
13.4 Steam Separator

The steam available from a boiler may be wet,
dry; or superheated; but in many cases there will
be loss of heat from it during its passage through
the steam pipe from the boiler to the engine
tending to produce wetness. The use of wet
steam in an engine or turbine is uneconomical
besides involving some risk; hence it is usual to
need to separate any water that may be present
from the steam before the latter enters the
engine. This is accomplished by the use of a
steam separator. Thus the function of a Figure 19 Steam Separator
steam separator is to remove the entrained
water particles from the steam conveyed to the steam turbine.
GZSCCET, Bathinda
14. STEAM TURBINE

The steam turbine is a prime mover in which the potential energy of the steam is transformed
into kinetic energy and latter in its turn is transformed into the mechanical energy of rotation
of the turbine shaft. The turbine shaft, directly or with the help of a reduction gearing, is
connected with the driven mechanism. Depending on the type of the driven mechanism a steam
turbine may be utilised in most diverse fields of industry, for power generation.
The steam turbines are mainly divided into two groups as:
a) Impulse Turbine
b) Reaction Turbine
In both types of turbine, first the heat energy

of the steam at high pressure is converted into
kinetic energy passing through the nozzles.
The turbines are classified as impulse or
reaction according to the action of high
velocity steam used to develop the power.
In impulse turbine, the steam coming out at a

very high velocity through the fixed nozzles
Figure 20 Impulse and Reaction Turbine
impinges on the blades fixed on the periphery
of a rotor. The blades change the direction of the steam flow without changing its pressure. The
resulting motive force (due to the change in momentum) gives the rotation to the turbine shaft.
In the reaction turbine, the high pressure steam from the boiler is passed through the nozzles.
When the steam comes out through this nozzles the velocity of the steam increases relative to
the rotating disc. The resulting reaction force of the steam on nozzle gives the rotating motion
to the disc and the shaft. The shaft rotates in the opposite direction to the direction of the steam
jet.
In an impulse reaction turbine, the steam expands both in fixed and moving blades
continuously as the steam passes over them. Therefore, the pressure drop occurs gradually
and continuously over both moving and fixed blades.
GZSCCET, Bathinda
14.1 Compounding of Steam Turbine

If the entire pressure drop from boiler pressure to condenser pressure is carried out in single
stage nozzle, then the velocity of the steam entering into the turbine could be very high of the
order of 1500 m/sec. The turbine rotor velocity will be very high, of the order of 30,000 r.p.m
as it is directly proportional to the steam entering velocity. Such high R.P.M. of the turbine
rotor is not useful for practical purpose and a reduction gear is necessary between the turbine
and external equipment driven by the turbine. There is also danger of structural failure of the
blade due to excessive centrifugal stresses. Therefore the velocity of the blades is limited to
400 m/sec.
The velocity of the steam at the exit of the turbine is sufficiently high when single stage blades
are used. This gives a considerable loss of kinetic energy (about 10 to 12%). The above-
mentioned difficulties associated with the single stage turbine can be solved by compound. The
combinations of stages are known as compounding. The different methods of compounding
are:
1. Velocity Compounding
2. Pressure Compounding
3. Pressure And Velocity Compounding
14.1.1 Velocity Compounding

There is only one set of nozzles and two or more rows of moving blades. There is also
a row of fixed blades in between the moving blades. The function of fixed blade is only
to direct the steam coming out from first moving row to next moving row. The heat
energy drop takes place only in the nozzle at the first stage and it converts into kinetic
energy. The kinetic energy of the steam gained in the nozzles is successively used by
the rows of moving blades and finally exhausted from the last row of the blades on the
turbine rotor. The function of the fixed blades is merely to turn the steam into the
direction required for entry into the next row of rotor blades without altering pressure
and velocity of the steam. A turbine working on this principle is known as velocity
compounded impulse turbine.
14.1.2 Pressure Compounding

A number of simple impulse turbine sets arranged in series is known as pressure
compounding. In this arrangement, the turbine is provided with one row of fixed blades
GZSCCET, Bathinda
at the entry of each row of moving blades. The total pressure drop of the steam does
not take place in a single stage nozzle but is divided equally in all the rows of fixed
blades which work as nozzles.
Figure 21 Pressure Compounded Steam Turbine
14.1.3 Pressure and Velocity Compounding

This compounding is a
combination of pressure
and velocity compounding.
The total pressure drop of
the steam from boiler to
condenser pressure is
divided into a number of
stages as done in pressure
compounding and velocity
obtained in each stage is
also compounded. This Figure 22 Pressure and Velocity Compounding
arrangement requires less
stages and compact turbine can be designed for a given pressure drop. This
compounding has an advantage of pressure compounding to provide higher pressure
drop in each stage and hence less number of stages and an advantage of velocity
compounding to reduce the velocity of each blade row.
GZSCCET, Bathinda
14.1.4 Advantages and Disadvantages of Velocity Compounding

Advantages:
a) It requires less number (2 to 3 only) of stages, therefore initial cost is less.

b) The space required is less.
c) The system is easy to operate and more reliable.
d) The turbine housing need not be made strong as pressure in the housing is considerably
less because the total pressure falls in the nozzle only.
Disadvantages:
a) The friction losses are too larger due to the high velocity of steam.
b) The maximum blade efficiency and efficiency range decreases with an increase in
number of stages.
c) The power developed in each successive blade row decreases with an increase in
number of rows, even though all the rows require same space, material and initial cost.
Therefore all the stages are not economically used. Velocity compounded steam
turbines are generally used as drives for centrifugal compressors, centrifugal pumps,
and small generators and feed pumps of high capacity power plants.
14.2 Losses in Steam Turbine

The causes for the energy losses in steam turbines are listed below:
Residual Velocity Loss- The steam leaves the turbine with some absolute velocity. The energy
loss due to absolute exit velocity of steam is equivalent to Vaex2/2gJ kJ/kg, where Vaex is
absolute velocity of steam leaving the turbine. The residual velocity loss is 10to 12% in a single
stage impulse turbine. This loss is reduced by using the multistage.
Loss Due To Friction and Turbulence- Friction loss occurs in nozzles, turbine blades and
between the steam and rotating discs. The friction loss in the nozzle is taken into account with
introducing factor ‘nozzle efficiency’. The loss due to friction and turbulence is about 10%.
Leakage Loss- The leakage of steam occurs at the points mentioned below:
a) Between the turbine shaft and bearing.
b) Between the shaft and stationary diaphragms carrying nozzle in case of reaction turbine.
c) Leakage at the blade tips in the glands.
GZSCCET, Bathinda
d) Leakage of steam through the glands.
The total leakage loss is about 1 to 2%.
Loss Due To Mechanical Friction- The loss due to friction between the shaft and bearing comes
under this category. Some loss also occurs in regulating the valves. This friction loss can be
reduced with the help of an efficient lubricating system.
Radiation Loss- The heat is lost from the turbine to the surroundings as its temperature is higher
than atmospheric temperature. Usually the turbines are highly insulated to reduce this loss. The
loss due to radiation is always negligible.
Loss Due To Moisture- The steam contains water particles passing through the lower stages of
the turbine as it becomes wet. The velocity of the water particles is less than the steam and
therefore the water particles have to be dragged along with the steam and consequently part of
the K.E. of the steam is lost.
14.3 Governing of Steam Turbine

The main function of the governing is to maintain the speed constant irrespective of load on
the turbine. The different methods which are commonly used for governing the steam turbines
are listed below:
1. Throttle Governing
2. Nozzle Control Governing
3. By-Pass Governing
4. Combination of Throttle and Nozzle Governing
5. Combination of Throttle and By-Pass Governing
14.3.1 Throttle Governing

The quantity of steam entering into the turbine is
reduced by the throttling of the steam. The throttling is
achieved with the help of double heat balanced valve
which is operated by a centrifugal governor through the
servo-mechanism. The effort of the governor may not be
sufficient to move the valve against the piston in big Figure 23 Throttle Governing
units. Therefore an oil operated relay is incorporated in the
circuit to magnify the small force produced by the governor to operate the valve.
GZSCCET, Bathinda
14.3.2 Nozzle Control Governing
In this method of control, the steam

supplied to the different nozzle groups is
controlled by uncovering as many steam
passages as necessary to meet the load by
poppet valves. An arrangement often
used for large steam power plants is
shown in fig. The numbers of nozzles
supplying the steam to the turbine are
divided into three groups and the supply
to these nozzles is controlled by the three
valves.
Figure 24 Nozzle Control Governing
14.3.3 By-Pass Governing

More than one stage is used for
high pressure impulse turbine
to reduce the diameter of the
wheel. The nozzle control
governing cannot be used for
multi stage impulse turbine due
to small heat drop in first stage.
It is also desirable in multistage
impulse turbine to have full
admission into high pressure
stages to reduce the partial
admission losses. In such cases Figure 25 By-Pass Governing
by-pass governing is generally

employed.
GZSCCET, Bathinda
14.4 Turbine Troubles

The following troubles may occur during the running of turbines which may cause the damage
to the turbines:
 Loss of blade shrouding

 Damage of the seal
 Failure of a bearing or whipping of shaft because of improper lubricating-oil pressure;
temperature or viscosity
Sudden increase in the vibration of the turbine is the most usual indication of any trouble caused
during running of the turbine.
14.5 Blade Materials for Turbines

The creep phenomenon is the main criteria in selection of blade material especially for high
temperature region. 1% Cr-Mo-V alloy and stainless steels having 12% Cr are widely used.
Austenite alloys are preferred for still higher temperature.
Blades of L.P. stage, though, at the low temperature end have to withstand the effect of
corrosion and erosion due to water droplets (0.25mm), about 10-12% stainless iron is
commonly used. New materials such as titanium, plastics reinforced with carbon having a
lower specific weight and higher strengths are also considered as they have high tensile strength
(70 kgf/mm2).
GZSCCET, Bathinda
15. ALTERNATOR
The alternator is universally used in automotive applications. It converts mechanical energy

into electrical energy, by electro-magnetic induction.
In a simple version, a bar

magnet rotates in an iron yoke
which concentrates the
magnetic field. A coil of wire is
wound around the stem of the
yoke. As the magnet turns,
voltage is induced in the coil,
producing a current flow.
When the North Pole is up, and
South is down, voltage is
induced in the coil, producing
current flow in one direction.
Figure 26 alternator
As the magnet rotates, and the
position of the poles reverses, the polarity of the voltage reverses too, and as a result, so does
the direction of current flow. Current that changes direction in this way is called alternating
current, or AC. The change in direction occurs once for every complete revolution of the
magnet.
15.1 Theory of Operation

Alternators generate electricity by the same principle
as DC generators. When magnetic field lines cut
across a conductor, a current is induced in the
conductor. In general, an alternator has a stationary
part (stator) and a rotating part (rotor). The stator
contains windings of conductors and the rotor contains
a moving magnetic field. The field cuts across the
conductors, generating an electrical current, as the
Figure 27 Alternator Working Principle
mechanical input causes the rotor to turn.
GZSCCET, Bathinda
The rotor magnetic field may be produced by induction (in a "brushless" generator), by
permanent magnets, or by a rotor winding energized with direct current through slip rings and
brushes. Automotive alternators invariably use brushes and slip rings, which allows control of
the alternator generated voltage by varying the current in the rotor field winding. Permanent
magnet machines avoid the loss due to magnetizing current in the rotor but are restricted in
size owing to the cost of the magnet material. Since the permanent magnet field is constant,
the terminal voltage varies directly with the speed of the generator. Brushless AC generators
are usually larger machines than those used in automotive applications.
15.2 Alternator Protection
An alternator is an important aspect of a power plant's electrical system. Any kind of obstacle
in its performance can mar the working of the power plant's overall electrical system. It is for
this reason that it requires adequate protection systems to prevent any kind of hindrance to
the power plant's functionality.
The main types of protection system are:
1. Over Current Protection
2. Reverse Power Protection
15.2.1 Over Current Protection

Every alternator has an over current protection. With the help of this trip, the alternator and
distribution system can be protected from various faults but the main thing to be considered
in this method is to maintain power to the distribution system till the time the alternator trips
on any other protection devices.
For this reason, the protection device has been designed in such a way that in case the over
current is not high enough, a time delay provided by an inverse definite minimum time (IDMT)
relay occurs, which prevents the alternator from tripping in case the over current values reduces
back to normal within the IDMT characteristics. But in case of a major fault such as short
circuit, the alternator will trip instantaneously without any delay, protecting all devices on the
distribution system. Overload of alternator is caused either due to increased switchboard load
or serious fault causing very high current flow.
GZSCCET, Bathinda
If sudden over load occurs then, the load is reduced with the help of preferential trips which
removes non-essential load such as of air conditioning, ventilation fans etc., from the
switchboard. These preferential trips are operated by relays which are set to about 110% of
the normal full load of alternator.
15.2.2 Reverse Power Protection

There is not much difference between an alternator and electric motors from the engineer's
perspective. They are both based on similar principles. So just imagine what would happen if
an alternator suddenly would act as a motor. This is only possible in systems where two or
more generators are running in parallel.
Hence this type of protection system is used only if there is more than one alternator on board
a ship. The system is designed in such a way that it will release the breaker and prevent
motoring of alternator if a reversal of power occurs. This protection device is also used to
prevent damage to the prime mover, which might be stopped due to some fault. Though it is
extremely difficult to detect reverse current with an alternating current system, reverse power
can be detected and protection can be provided by reverse power relay.
GZSCCET, Bathinda
16. STEAM CONDENSER

A steam condenser is a device or an appliance in which steam condenses and heat released by
steam is absorbed by water. The use of condenser in the power plant improves the efficiency
of the power plant by decreasing the exhaust pressure of the steam below atmosphere. Another
advantage of the condenser is that the steam condensed may be recovered to provide a source
of good pure feed water to the boiler and reduces the water softening plant capacity to a
considerable extent.
The maximum possible thermal efficiency of a power system is given by (T1 – T2)/T1 where
T1 and T2 are the supply and exhaust temperatures. This expansion of efficiency shows that the
efficiency increases with an increase in temperature T1 and with the decrease in temperature
T2. The maximum value of temperature T1 of the steam supplied to a steam prime-mover is
limited by the material consideration. The temperature T2 can be reduced if the exhaust of the
steam prime mover takes place below the atmospheric pressure. This is because; there is
definite relation between the steam temperature and pressure. Low exhaust pressure means low
exhaust temperature. The steam cannot be exhausted to atmosphere if it is expanded in the
turbine below atmospheric pressure. Under this condition, the steam is made to exhaust in a
vessel known as condenser where the pressure inside is maintained below the atmospheric
pressure by condensing the steam with the circulation of the cold water.
A closed vessel in which steam is condensed by abstracting heat from steam and the pressure
is maintained below atmospheric pressure is known as condenser. The efficiency of the steam
plant is considerably increased by the use of condenser.
16.1 Advantages of Condenser

The advantages obtained by incorporating a condenser in the steam power plant are listed
below:
I. The condensed steam from the condenser is used as feed water for boiler. Using the
condensate as feed for boiler reduces the cost of power generation as the condensate is
supplied at higher temperature to the boiler and it reduces the capacity of the feed water
cleaning system.
II. The efficiency of the plant increases as the enthalpy drop increases by increasing the
vacuum in the condenser. The specific steam consumption of the plant also decreases
as the available enthalpy drop or work developed per kg of steam increases with
decrease in back pressure by using condenser.
III. The deposition of salt in the boiler is prevented with the use of condensate instead of
using the feed water from outer source with contained salt. The deposition of salt in
boiler shell also reduces the boiler efficiency. This is particularly important in marine
steam power plant.
GZSCCET, Bathinda
The use of condenser in steam power plant reduces the overall cost of generation by increasing
the thermal efficiency of the power plant.
The efficient condenser plant must be capable of producing and maintaining a high vacuum
with the quality of cooling water available and should be designed to operate for the prolonged
periods without trouble.
The desirable features of good condensing plant are:
a. Minimum quantity of circulating water.

b. Minimum cooling surface area per KW capacity.
c. Minimum auxiliary power.
d. Maximum area of condensed per m2 of surface area.
The effect of low vacuum is very pronounced. The efficiency of the power plant depends to a
greater extent on the pressure at the exhaust than the high pressure condition of the steam at
inlet.
16.2 Corrosion and Scale Formation in Condenser Tubes and

Their Prevention
The efficiency of the condenser tube depends upon maintenance of heat transfer surface
cleanliness, adjustment of water flow of best economy and reduction of air-leakage to a
minimum. The importance of water flow and prevention of air leakage are already discussed.
The success of heat transfer with minimum power consumption for a long time mostly depends
upon the clean lines of the condenser tubes. The corrosion and scale formation are the common
phenomenon in condenser tube during operation due to the action of chemical compounds and
deposited collected on the tube surface carried with the water. The life of the tubes is also
reduced due to erosion which ids the effect of abrasive materials (like sand) carried with
cooling water.
In the average condenser installation on a river or lake, provision must be made for cleaning
the condenser tubes. The fouling of tubes occurs because of algae, organic matter, leaves or
other floating debris. Grills and screens removes most of the floating debris, even the small
particle will eventually accumulate on the tubes and reduces the heat transfer. It is also desirable
to clean the condenser while it is under load. A single pass condenser during working condition
can be cleaned by using back-washing. A valve arrangement is generally provided for back-
washing purpose.
GZSCCET, Bathinda
With the most waters, there is general tendency for algae growth to build up on the tube surface.
Algae growth is considerably more rapid under warm water conditions therefore summer
periods are of the greatest trouble from this source in North American power plants. The algae
often serve as a binder for mud or scale and if algae deposits are removed or controlled, other
deposits are also minimised as well.
In closed type cooling system, where the cooling water is concentrated by evaporation, the
possibility of scale formation is more if the water is not chemically treated.
Two general methods of treatment are used for condenser tubes cleaning. First is the
sterilization of the heat exchange surface of the condenser. This sterilization can be
accomplished by a number of commercially available compounds as copper sulphate, chlorine,
chlorinated phenols or mercurial.
16.3 Material for Steam Condenser

The application of stainless steel tubing for surface condenser is approximately 30 years old.
The major growth of this application has occurred in past two decade only. Originally these
materials were only considered for highly corrosion environments or areas exposed to severe
erosion. The cost of stainless steel tubes and available heat transfer data, a decade ago,
restricted there used to the really difficult problems areas. Since that time, a number of
important advances have been achieved which have permitted a more use of these materials for
condenser application.
The determination of the overall heat transfer properties of stainless steel condenser tubes in
the early 1960 led to more extensive use of these materials. The popular types are 304 (72%
iron, 19% chromium, 9% nickel) and 316. 304 are used in cooling water environment with low
chloride concentrations and 316 are used for sea water environments.
In case of stainless steel tubes, the fouling is due to the formation of deposits from the cooling
water only but the fouling of the brass is caused by deposits and corrosion of the inside tube
surface also.
The overall corrosion resistance of stainless steel, 304 type is excellent for condenser tube
service both the interior and exterior surface resist the formation of corrosion product which
has an important influence on the heat transfer characteristics of the tubes. It offers excellent
erosion and corrosion resistance in fresh water, immunity to NH3 and sulphide attack and the
elimination of potentially troublesome copper ions in feed water.
GZSCCET, Bathinda
17. COOLING WATER SYSTEM

The cooling water system is one of the most important systems of power plant and its
availability predominantly decides the plant site. The high cost of water makes it necessary to
use cooling towers for water cooled condenser.
The main steam condenser performs the dual function of removing this rejected energy from
the plant cycle and keeping the turbine back pressure at the lowest possible level. The rejected
energy must be returned to the atmosphere. The condenser does this by transferring the latent
heat of the exhaust steam to water exposed to the atmosphere. This water is called circulating
or cooling water. The cooling water requirement in an open system is about 50times the flow
of the steam to the condenser.
In power plants the hot water from condenser is cooled in cooling tower, so it can be reused in
condenser for condensation of steam. In a cooling tower water is made to trickle down drop by
drop so that it comes in contact with the air moving in the opposite direction. As a result of this
some water is evaporated and is taken away with air. In evaporation the heat is taken away
from the bulk of water, which is thus cooled.
Factors affecting cooling of water in a cooling tower are:
1. Temperature of air.
2. Humidity of air.
3. Temperature of hot air.
4. Size and height of tower.
5. Velocity of air entering tower.
6. Accessibility of air to all parts of tower.
7. Degree of uniformly in descending water.
8. Arrangement of plates in tower.
17.1 Classification of Cooling Tower

The cooling towers may classified as follows:
1) Natural Draught Cooling Tower

2) Mechanical Draught Cooling Tower
a) Forced Draught Cooling Tower
b) Induced Draught Cooling Tower
GZSCCET, Bathinda
17.1.1 Natural Draught Cooling Tower

In this type of tower, the hot water from the
condenser is pumped to the troughs and
nozzles situated near the bottom. Troughs
spray the water falls in the form of droplets
into a pond situated at the bottom of the
tower. The air enters the cooling tower
from air openings provided near the base,
rises upward and takes up the heat of
falling water.
Advantages
Figure 28 Natural Draught Cooling Tower
A. Low operating and maintenance cost.
B. It gives more or less trouble free operation.
C. Considerable less ground area required.
D. The enlarged top of the tower allows water to fall out of suspension.
Drawbacks
A. High initial cost.

B. Its performance varies with the seasonal changes in dry bulb temperature and relative
humidity of air.
17.1.2 Mechanical Draught Cooling Tower

In these towers the draught of air for cooling the tower is produced mechanically by means of
propeller fans. These towers are usually built in cells or units, the capacity depending upon the
number of cells used.
17.1.2.1 Forced Draught Cooling Tower

It is similar to natural draught tower as far as interior construction is concerned, but the sides
of the tower are closed from an air and water tight structure, except for fan opening at the
base for the inlet of fresh air, and the outlet at the top for the exit of air and vapour. There are
hoods at the base projecting from the main portion of the tower where the fans are placed for
forcing the air, into the tower.
GZSCCET, Bathinda
Advantages:
1) More efficient (than induced

draught).
2) No problem of fan blade erosion
(as it handles dry air only).
3) More safe.
4) The vibration and noise are
minimum.
Disadvantages: Figure 29 Draught Cooling Tower
1) The fan size is limited to 4 meters.

2) Power requirement high (approximately double that of induced draught system for the
same capacity).
3) In the cold weather, ice is formed on nearly equipments and buildings or in the fan
housing itself. The frost in the fan outlet can break the fan blades.
17.1.2.2 Induced Draught Cooling

Tower
Advantages:
1. The coldest water comes in

contact with the driest air
and warmest water comes in
contact with the most humid
air.
2. In this tower, the
recirculation is seldom a
problem. Figure 30 Induced Draught Cooling Tower
3. Lower first cost.
4. Less space required.
5. This tower is capable of cooling through a wide range.
GZSCCET, Bathinda
Disadvantages:
1. The air velocities through the packing are unevenly distributed and it has very little
movement near the walls and centre of the tower.
2. Higher H.P. motor is required to drive the fan comparatively. This is due to the fact that
the static pressure loss is higher as restricted are at base tends to choke off the flow of
higher velocity air.
17.2 Maintenance of Cooling Tower

The regular maintenance of cooling tower is very essential to achieve the desired cooling and
to reduce the depreciation cost. The maintenance of cooling tower includes the following:
1. The fan, motor housing should be inspected from time to time.

2. Motor bearing should be greased and gearbox oiled.
3. At least once in a year motor’s gear boxes should be checked for structural weakness.
4. The water spraying nozzles should be inspected regularly for clogging.
GZSCCET, Bathinda
18. GENERAL DESCRIPTION

18.1 Boiler Feed Pump
As the heart is to human body, so is the boiler feed pump to the steam power plant. It is used
for recycling feed water into the boiler at a high pressure for reconversion into steam. Two nos.
100% duty, barrel design, horizontal, centrifugal multistage feed pumps with hydraulic
coupling are provided for each unit. This is the largest auxiliary of the power plant driven by
3500 KW electric motor. The capacity of each boiler at GURU NANAK DEV THERMAL
PLANT is 375 tones/hr. The pump which supplies feed water to the boiler is named as boiler
feed pump. This is the largest auxiliary in the unit with 100% capacity which takes suction of
feed water from feed water tank and supplies to the boiler drum after preheating the same in
HP-1, HP-2 and economizer. The delivery capacity of each boiler feed pump is 445 tones/hr.
to meet better requirements corresponding to the various loads, to control steam temperature,
boiler make up water etc. The detailed particulars checking of protections and inter locks,
starting permission etc. are as below:-
Particulars of BFP and its main motor:- The 110 MW turboset is provided with two boiler feed
pumps, each of 100% of total quantity. It is of barrel design and is of horizontal arrangement,
driven by an electric motor through a hydraulic coupling.
Type 200 KHI
No. of stages 6
Delivery capacity 445 t/hr.
Feed water temperature 158°C
Speed 4500 rpm
Pressure at suction 8.30 kg/cm²
Stuffing box mechanical seal
Lubrication of pump by oil under pressure
And motor bearing supplied by hydraulic coupling
Consumption of cooling water 230 L/min.
GZSCCET, Bathinda
18.2 Water Treatment Plant

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

Coal Mill pulverizes the raw coal into a fine powder before it is burnt in the boiler furnace. The
pulverizing of coal is achieved with the impact of falling steel balls, weighing 52.5 tonnes,
contained in the mill drum rotating at a slow speed of 17.5 r.p.m. The raw coal is dried, before
pulverizing, with inert hot flue gases tapped from the boiler. Three coal mills each with a
pulverizing capacity of 27 T/hr. are provided for one unit.
18.4 Induced Draught Fan

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

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

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

Coal unloaded by the wagon tippler is carried to crusher house through conveyors for crushing.
Two nos. hammer type coal crushers are provided, which can crush coal to a size of 10 mm.
The crushed coal is then supplied to Boiler Raw Coal Bunkers. The surplus coal is carried to
coal storage area by series of conveyors. Crushing of coal is an essential requirement for its
optimum pulverizing and safe storage.
18.8 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 tons
of water per hour by 10°C. 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.
18.9 Boiler
It is a single drum, balanced draught, natural circulation, reheat type, vertical combustion
chamber consists of seamless steel tubes on all its sides through which water circulates and is
converted into steam with the combustion of fuel. The temperature inside the furnace where
the fuel is burnt is of the order of 1500 C. The entire boiler structure is of 42meter height.
18.10 Boiler Chimney

The flue from the boiler, after removal of ash in the precipitators, are let off to atmosphere
through boiler chimney, a tall ferro-concrete structure standing as high as the historic
QutabMinar. 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.
18.11 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.
GZSCCET, Bathinda
19. COAL MILLING PLANT

Since G.N.D.T.P. units are primarily coal fired units so each boiler is provided with closed
milling circuits to pulverize the raw coal which is received from coal conveying system after
coal crushes before it is fired in the furnace. The necessity of pulverizing the coal is to be
ensuring its maximum possible combustion in the furnace. The coal data for units are: -
COAL DATA UNITS 1 & 2 UNITS 3 & 4
Type of Coal Bituminous Bituminous
Net Calorific 4300 Kcal/kg 4727 Kcal/Kg
Value Moisture 10 % 7.5 %
Ash Content 30 % 32 %
Volatile Matter Incombustible 24 % 27 %
Inlet of Coal 10 mm 20 mm
Raw coal of maximum size 10 mm – 20 mm is pulverized in the milling circuit and the output
from the mill is fine coal.
19.1 Coal Mill

These are mainly of two types:-
a) Ball Mills
b) Bowl Mills
19.1.1 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.
GZSCCET, Bathinda
19.1.2 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.
19.2 Wagon Tippler

The tippler is designed to work on the following cycle of operation:-
Tipping 90 seconds
Pause 5-12 seconds
Return 90 seconds
Weighing 30 seconds
Total 215-222 seconds
Allowing 85 seconds for wagon changing it will be seen that 12 eight-wheel wagons or 24 four-
wheel wagons per hours can be tipped. However since the coal carrying capacity is 500 tones
per hour load of 12 wagons comes to 8 to 9 per hour.
19.3 Crusher House

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

It is main part of steam generator it is an assembly of a large no. of vertical riser tubes embedded
in refractory walls. There are two boilers one for each unit. The type of the boiler is natural
circulation radiant single reheat boiler. The four refectory walls make a closed box called
furnace. The walls are given special names. These are:-
1. Right wall consisting 130 tubes

2. Left wall consisting 130 tubes
3. Front wall consisting 181 tubes
4. Rear wall consisting 181 tubes
On the right and left wall, the wind boxes are installed. Thus there are four furnace coroners.
The water tubes cool the walls by absorbing the heat and transferring it to the water running in
them. The tubes are embedded in refractory walls very close (the gap between two tubes is 10
mm). The inner diameter of the tubes is 63.5mm.
Justification of the boiler type:-
The type of boiler is Water Tube, Natural Circulation, Radiant and Single Reheat boiler.
The meaning of each word has been explained below-
 Water Tube- It mean the water runs in the tubes and the fire is outside the tubes.
 Natural circulation- The circulation word mean how the water is raised in the walls. We
know that to move the water upwards we have to supply some external power e.g. some
pump system but here a law does this work naturally. The saturated water collected at
the bottom known as ring header. The water rises from it in riser pipes naturally. There
is a two phase mixture of water and steam in risers. There is a difference between the
densities of the mixture and saturated water in ring header. Also there is a static head.
Due to the result of both factors there is natural circulation operates in boiler.
 Radiant Type: In radiant heat boilers, metal tubes or pipes are embedded in walls and
floors, which can carry hot water or steam. A water boiler, which is usually kept in the
cellar, is used for heating water. The heated water is then pushed into the circulation
system through a pumping system. When hot water circulates through these pipes,
floors and ceilings get heated through radiant heat. Water which has cooled down after
heating is again pumped back into the boiler for reheating.
GZSCCET, Bathinda
 Single Reheat: It implies that the system is reheated only once. When the steam goes to
the turbine its temperature decreases from 540 deg to 343 deg. It is then send to reheater
to increase the temp to again 540 deg.
1. It should be absolutely reliable and capable of making maximum amount of steam for
minimum fuel consumption, attention, initial cost and maintenance charges.
2. It should be light in weight and should occupy small space.
3. It should be capable of quick starting and meeting rapidly large variation of load
demands.
4. The water surface and tube should be so arranged so as to avoid priming.
5. The tubes should not accumulate soot or water deposits.
6. The refractory system should be as little as possible, but sufficient to secure easy
ignition and smokeless combustion of fuel on reduced load.
GZSCCET, Bathinda
21. BIBLIOGRAPHY
 https://en.wikipedia.org/wiki/Thermal_power_station
 https://en.wikipedia.org/wiki/Electricity_sector_in_India
 https://en.wikipedia.org/wiki/Boiler
 https://en.wikipedia.org/wiki/Rankine_cycle
 https://en.wikipedia.org/wiki/Power_station
 http://spxcooling.com/coolingtowers
 http://en.wikipedia.org/wiki/Rankine_cycle
 http://en.wikipedia.org/wiki/Boiler
 http://en.wikipedia.org/wiki/Power_station
 http://en.wikipedia.org/wiki/Water-tube_boiler
 http://en.wikipedia.org/wiki/Surface_condenser
 http://en.wikipedia.org/wiki/Cooling_tower_system
 http://www.brighthubengineering.com/marine-engines-machinery/42651-marine-
alternators-protection-systems-used-on-board-ships/
 http://indianpowersector.com/home/power-station/thermal-power-plant/
 Babcock & Wilcox Co. (2005). Steam: Its Generation and Use (41st editioned.).ISBN
0-9634570-0-4.
 Dr. R.K. Rajput, Power Plant Engineering Laxmi publication (P) Ltd, 2007.
 Arora, Domkundwar, A course in Power Plant Engineering Dhanpat Rai & Co., 2008.
 Domkundwar, Kothandaraman, A course in Thermal Engineering Dhanpat Rai & Co.,
2010.
 Manual of Guru Nanak Dev Thermal Plant, Bathinda
GZSCCET, Bathinda

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4 Months Industrial Training Report Page | 1/69

4MONTHS INDUSTRIAL TRAINING

GZS Campus College of Engineering & Technology,

1. WHAT IS A THERMAL POWER PLANT .......................................................................... 9

1.1 Concept of Thermal Power Station ................................................................................ 10

1.2 General Layout of Thermal Power Plant ....................................................................... 11

1.2.1 Coal and ash circuit ................................................................................................. 11

1.2.2 Air and gas circuit ................................................................................................... 12

1.2.3 Feed water and steam circuit................................................................................... 12

1.2.4 Cooling water circuit............................................................................................... 12

2. HISTORY OF THERMAL POWER PLANTS ................................................................... 13

3. INTRODUCTION TO GNDTP ........................................................................................... 14

4. BRIEF HISTORY OF PLANT ............................................................................................ 15

5. SITE SELECTION .............................................................................................................. 16

7. PLANT AT A GLANCE ..................................................................................................... 18

8. PLANT SALIENT FEATURES .......................................................................................... 20

8.1 Project Area ................................................................................................................... 20

8.3 Steam Turbine ................................................................................................................ 20

8.5 Boiler Feed Pumps ......................................................................................................... 21

8.6 Circulating Water Pumps ............................................................................................... 21

8.7 Cooling Towers .............................................................................................................. 22

8.8 Coal Pulverising Mills ................................................................................................... 22

8.9 Rating Of 6.6 kv Auxilliary Motors ............................................................................... 22

9. WORKING PRINCIPLE OF THERMAL POWER PLANT .............................................. 23

10. WORKING OF THERMAL PLANT ................................................................................ 27

11. BOILER ............................................................................................................................. 29

11.1 Introduction .................................................................................................................. 29

11.2 Classification of Boilers ............................................................................................... 30

11.2.1 Horizontal, Vertical or Inclined ............................................................................ 30

11.2.2 Fire Tube And Water Tube ................................................................................... 30

11.2.3 Externally Fired And Internally Fired................................................................... 31

11.2.4 Forced Circulation And Natural Circulation......................................................... 32

11.2.5 High Pressure And Low Pressure Boiler .............................................................. 32

11.2.6 Single Tube And Multi-Tube Boiler ..................................................................... 33

11.3 Selection of a Boiler..................................................................................................... 33

11.4 Performance of Boiler .................................................................................................. 33

12. BOILER MOUNTINGS .................................................................................................... 34

12.1 Different types of Boiler Mountings ............................................................................ 34

12.1.1 Safety Valve .......................................................................................................... 34

12.1.2 Water Level Indicator ........................................................................................... 35

12.1.3 Pressure Gauge...................................................................................................... 35

12.1.4 Fusible Plug .......................................................................................................... 35

12.1.5 Feed Check Valve ................................................................................................. 36

12.1.6 Blow-Off Cock...................................................................................................... 36

12.1.7 Steam Stop Valve .................................................................................................. 37

13. BOILER ACCESSORIES ................................................................................................. 38

13.1 Economisers ................................................................................................................. 38

13.1.1 Design Requirement for an Economiser ............................................................... 39

13.1.2 Types of Economisers ........................................................................................... 39

13.1.3 Advantages of Economiser ................................................................................... 40

13.2 Air Preheater ................................................................................................................ 41

13.3 Superheater .................................................................................................................. 43

13.3.1 Types of Superheater ............................................................................................ 43

13.4 Steam Separator ........................................................................................................... 44

14. STEAM TURBINE ............................................................................................................ 45

14.1 Compounding of Steam Turbine .................................................................................. 46

14.1.1 Velocity Compounding ......................................................................................... 46

14.1.2 Pressure Compounding ......................................................................................... 46

14.1.3 Pressure and Velocity Compounding.................................................................... 47

14.1.4 Advantages and Disadvantages of Velocity Compounding.................................. 48

14.2 Losses in Steam Turbine .............................................................................................. 48

14.3 Governing of Steam Turbine ....................................................................................... 49

14.3.1 Throttle Governing................................................................................................ 49

14.3.2 Nozzle Control Governing .................................................................................... 50