REPORT

OF
PROJECT SEMESTER TRAINING
COMPLETED AT

G.H.T.P, LEHRA MOHABBAT

WITH
PROJECT- BOILER MAINTAINANCE

SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

BY
PARDEEP SINGH
(21003122)

MECHANICAL ENGINEERING SECTION

YADAVINDRA COLLEGE OF ENGINEERING
PUNJABI UNIVERSITY, GURU KASHI CAMPUS,
TALWANDI SABO – 151302 (PUNJAB), INDIA
MAY 2014

1
 INDEX
Sr. No. Topic Page No.

1. Acknowledgement 1.

2. Brief history of G.H.T.P.LehraMohabbat 2.

3. Gernal project information 3.

4. G.H.T.P. Overview 4.
5. Gernal process of power generation 5. to 6.

6. Coal Handling Plant 7. to 15.

7. Coal Pulverising System 16. to 20.

8. D.M. Plant 21. to 24.

9. Boiler Feed Water Pump 25. to 29.

10. Steam Generator 30. to 37.

11. Boiler Air and Gas Scheme 38. to 41.
12. Steam Turbine 42. to 49.

13. Power Generator 50.

14. Cooling Towers 51. to 52.

15. Cooling Water System 53. to5 4.

16. Hydrogen Gas Plant 55. to 57.

17. Compressor House 58. to 59.
18. Conclusion 60.

2
 ACKNOWLEDGEMENT

A great many thanks to Er. D.S.BHULLAR who granted me permission to under go training in
G.H.T.P. LEHRA MOHABBAT. It was thankful to Er. JASKARN SINGH Under whose
guidance I underwent our training and that made all the difference. I am indebted to him because it
was he whose constant barrage of questions kept our gray cells our working overtime and helps us
fathom the intricacies of this trade. Many a posers by them gave us food for thought. We were
enlightened on the practical aspects of engineering.

At the grass root level were the real people who helped us. They were the machine
operators, the shift In charge and other workmen who explained the working of a variety of
instruments and the various mechanisms governing their operation. It was the informal talk with
them which taught us many a nuances of the trade. In the end I would like to give a big thanks to
the whole of the G.H.T.P. LEHRA MOHABBAT family for their wholehearted support toward
this endeavor of ours.

3
 BRIEF HISTORY OF GHTP

Ever widening gap between the power demand and its availability in the state of Punjab was one of
the basic reasons for envisaging a thermal plant at ‘Lehra Mohabbat” Dist. Bathinda. The other
factors favoring the installation of this thermal were low initial cost and less generation period as
compared to hydro electric generating station, its good railway connection for fast proximity to
load center. The foundation of the plant was laid in 1995 and it was named “Guru Hargobind
Thermal Plant”. “Guru Hargobind Thermal Plant” has two units of stage I each of capacity
210MW and two units of stage II each of capacity 250MW. The 220KVswitch yard and boiler was
light up 2nd May 1997 by Sukhdev Singh Handsaw, Minister of Punjab. The maximum power of
the plant is used in agriculture industry load and rural electrification.

Stage I
The first unit was commissioned on 29/12/1997
The second unit was commissioned on 16/10/1998

Stage II
The third unit was commissioned on 16/10/2008
The fourth unit was commissioned on 31/01/2009

The power availability from the plant now meets 20-25% of the total power requirement in Punjab.
It has gone a long way in ushering prosperity in the state by emerging a large number of
agricultural pumping sets, more industrial connections, 100% rural electrification, increased
employment potential reliability and improvement in continuity of supply and system voltage and
removal of power cuts to a great extent. It has also led to fast development to about 3000 persons.
The main companies whose technology pawed the way of this plant are “TATA Honeywell” &
“BHEL” in turbine and boiler control.

The following considerations have to be examined in detail before selection of site for a plant:-
1. Availability of fuel such as coal.
2. Ash disposal facilities.
3. Space requirements.
4. Nature of land.
5. Most important availability of water.
6. Availability of labor.
7. Transport facilities.
8. Public Society problems such as pollution.
9. Development of backward area

4
 GERNAL PROJECT INFORMATION

1. Location Between 129 km and 132 km mile stones on Bathinda,

Barnala Road on State Highway No. 12.
2. Main Features 1. Highest generation during 2000-01
2. Highest P.L.F. during March, 2001
3. Lowest Oil consumption during Feb, 2001
4. Lowest D.M. water make up during August, 2000
3. No. of Power Houses 4
4. No. of Units 4
5. Total Generating Capacity 2 x 210 MW = 420 MW (Stage I)
2 x 250 MW = 500 MW (Stage II)
Total Capacity = 920 MW
6. Source Of Water Supply Bathinda Branch Of Sirhind Canal
7. Fuel Used Coal from North Karanpura.
Coal field of Central Coal field Ltd.
A subsidiary Company of coal India Ltd.
L.D.O (Light Diesel Oil)
H.F.O (Heavy Furnace Oil)
8. Turbines 210 MW and 250MW single shaft reaction turbines, tandem
coupled 3000 rpm double flow exhaust, reheat type with initial
parameters of 150 kg/sq.cm. And 535oC
9. Generators 247 MVA, 15.75 KV, 0.85 lag, 50 Hz, 3 Phase, double star two
pole, Horizontal, Cylinder rotor type.
294MVA, 16.5 KV, 0.85 lag, 50 Hz, 3 phase, double star two
pole, Horizontal, Cylinder rotor type
10. Commissioning Stage I
The first unit was commissioned on 29/12/1997
The second unit was commissioned on 16/10/1998

Stage II
The third unit was commissioned on 16/10/2008
The fourth unit was commissioned on 31/01/2009
11. Cost of Project Stage I - Rs. 1189 Crores
Stage II - Rs. 2123 Crores
12. Total Energy Contribution 8059.20 Million units
Annually
13. Cost Per Unit Rs. 3.17

5
 3.1 GERNAL PROJECT INFORMATION

Fig. 4.1 G.H.T.P. THERMAL PLANT PRACTICAL OVERVIEW

6
 GERNAL PROCESS OF POWER GENERATION

In the general process of power generation a generating unit of thermal plant consists of boiler unit,
a turbine unit with accessories a generator unit transformer and other equipments all arranged to
operate as complementary parts of a complete monolithic set.

The coal travels by conveyor belt from the coal handling plant to the boiler bunkers from
where it is fed into pulverizing mills which grind the coal in to powder. This powdered coal is
carried from the mill by stream of air fan to the boiler burners, where it is blown in to the furnace
and burns like a gas. A forced draught fan provides additional controllable fair to the burners to
assist combustion. The product of combustion are dust and ash. The ash falls to the bottom of the
boiler and is periodically sluiced to the ash settling pits. The dust is carried in the fuel gases to the
precipitator where it is extracted by high voltage electrodes. The dust is then conveyed to setting
logons or removed by rode for sale. The cleared five gases pass via an induced draught fan to the
chimney.

The heat released by burning is absorbed by long lengths of tubing which from the boiler
walls. Inside the tubes, extremely pure water known as boiler feed water is converted by the heat in
to steam at high temperature and pressure. The steam is superheated in further tubes and passes to
high pressure turbine blades make the turbine rotation. After passing through the HP turbine the
steam is then returned to the boiler for reheating before passing in to the intermediate pressure
turbine and from there to low pressure turbine coupled to the turbine shaft is the rotor of generator,
a large cylindrical electromagnet so that when the turbine rotor rotates the generator rotates with it.
The generator rotor enclose in the stator which consists of large coils of copper bar in which
electricity is produced by the rotation of the magnetic field created by the rotor.

The electricity passes the stator winding to the transformer which increases its voltage so
that it can be transmitted over the power lines in to the grid system. Meanwhile, the steam which
has exhausted its useful energy in turning the turbine blades is turned back in to water in the
condenser to be used again in the boiler. Before entering the boiler at the economizer the water
pumped by condensate extraction pumps, heated in LP heater, dearated in derated. Increased in
pressure by the boiler feed pump and heated further in HP heaters.

The water through the economizer to the steam drum, then up through the furnace wall
tubing before returning to the steam drug for steam operation. The steam leaves the drug and is

7
heated further in the super heater on this way to the HP turbine. The Condenser contains tubing’s
through which the cold water is constantly pumped.

Thermal Plant Process

8
 Fig. 5.1

COAL HANDLING PLANT

 RECIEPT AND WEGHTMENT OF COAL:

Coal at GHTP received from Centre
Coal Ltd and Eastern Coal field Ltd of Coal India besides important coal from China. On receiving
coal, it is weighed on the electronic “in motion Way Bridge”. There are 2 numbers “In motion way
bridges”. Both can be put into service at a time. The speed of the train must be less than 10 Km/hr.
After weighment the rake is divided into equal batches consisting of about 15 wagons in each batch
for unloading.

9
 Fig. 6.1

 WEGON TIPPLER
After dividation in batch the wagon is send to the wagon tippler. Here the coal is unloaded
from the wagon with the help of wagon tippler. Tippler isd esigned as a way that it will lift
the wagon in easy way. In this mechnism, a platform is cut out of the size of wagon known
as tippler table. It is lifted up with the help of a servo motor connecting with a gear box.
That gear box is connected to a shaft that has a gear attached to it, is connected to a
mechanism with tippler table. When the command is given, the servo motor operates the
mechnism. It lifts the table and unloads the wagon. The coal goes on the Apron delt trough
the hopper.

10
 Fig. 6.2WEGON TIPPLER

 COAL CONVEYOR:
Coal conveyors are used to move coal around efficiently.
Coal arriving by train can be stocked for later use or taken straight to the coal bunkers. CHP
control room with remote control system helps to ensure that the conveyors take the coal to
the right bunkers.

11
 Fig. 6.3

 CONVEYING SYSTEM:
A belt conveyor consists of two or more pulleys, with a
continuous loop of material - the conveyor belt - that rotates about them. One or both of the
pulleys are powered, moving the belt and the material on the belt forward. The powered
pulley is called the drive pulley while the unpowered pulley is called the idler. The width of
the belt in G.H.T.P. is 2000mm.

 CRUSHER HOUSE:
Coal unloaded by the wagon tippler is carried to crusher house
through conveyors for crushing. There are two types of crusher in G.H.T.P. as given below-
1. Rotary breaker (primary crusher).
Rotary Breakers are used in the primary and secondary reduction
of ROM coal and in the separation of rock and mine refuse. This is accomplished through the
tumbling action of the rotating drum, which lifts and drops the feed material repeatedly until the
coal breaks down and exits the drum through the screen plate perforations while the rock and
refuse move through and are rejected at the discharge end.

12
 Fig. 6.4 ROTARI BREAKER

TECHANICAL DATA
Type : 12’*22’ roller mounted

Weight : 62 MT

Capacity : 750MT/hr

Material input size : 500mm

Material output size : 125mm

Motor rating : 180 HP, 415 volt

Nos. : 2

13
 2. Ring granulator (secondary crusher)

Fig. 6.5RING GRANULATOR

TECHANICAL DATA
Type : TRM-54
Capacity : 1000T/hr
Material input size : 300mm (max)
Material output size : 25mm
Motor rating : 737KW, 606 KV, 720 r.p.m
Nos. : 2

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 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 these purpose.

There is built in arrangements of bypassing the crusher by which the coal can be fed
directly to the conveyors bypassing crush.

14
 STACKING / RECLAIMING:

Fig. 6.6 COAL STACKING AREA

In coal stacking area crushed coal is stored for emergency (when no load comes to
power plant). Here a tone of coal is stored with the help of a heavy machine known as
stacker. It contains a bucket wheel, when no load comes to the plant then by the reverse
drive this bucket wheel reclaim the coal and it to the bunkers.

15
 6.7STACKER

 TROLLEY:
Tippler trolley is used to fill the bunkers with coal coming on the conveyor
from the coal handling plant. There are four trolleys in GHTP at the height of 53 m.

Fig. 6.8 TROLLEY

16
 BUNKER:
It is a very big cylindrical drum. It is used to store the coal which comes
from the CHP. It hanged at the height of 53m it placed right above the raw coal feeder and
connected with it by a large dia. Pipe. Hard coal and brown coal are the main energy
carriers in coal-fired power plants. Delivered by ship or by train, the coal is unloaded into
bunkers up to 30 m high. The coal is transported from these bunkers to the stockpiles of the
power plant via over ground or underground conveyor belt systems. Additional conveyor
belts feed, often via intermediate bunkers, purlverizer mills where the coal is converted into
a fine dust for subsequent combustion in the furnace. Reliable level measurement
guarantees uninterrupted feeding of the furnaces and point level sensors prevent overfilling
in the bunkers.

Fig. 6.9 COAL BUNKER

17
 RAW COAL FEEDER

In GHTP Lehra Mohabbat RC Feeder are used for control the Coal and this
feeder feed the coal to Bowl mills and Bow mills are Grinder the Coal and Convert into powder
shape. Transport coal from RC Bunker to coal mill by belt conveyor having drive motor connected
with dynadrive to control the coal feed. RC Bunker – 6 nos. one for each RC feeder fabricated
from sheet metal having capacity of 650 Tones approx. have been provided.

Fig. 6.10 RAW COAL FEEDER

RC Feeder are 6 for each unit 4 RC feeder work at a time and 2 is stand by position. In GHTP the
RC Feeder is control the coal by a conveyor belt and it is operated by 3 phase electric motor.

 COAL FEEDER:
• The variable speed coal feeder feeds coal from the bunkers to the mill.
• It uses a conveyor to move coal through a fixed gap at a precisely controlled speed.
• Varying the speed controls the amount of coal supplied to the boilers.
• These are precision bits of equipment that have to move exact amounts of coal.
• They can move 650 Tones approx. of coal in an hour.

18
 Fig. 6.11 coal feed sys.

COAL PULVERISING SYSTEM

At GHTP Bowl Mills have been installed for pulverizing the raw coal. Coal of
maximum size of 25mm is received in Raw Coal Bunkers from Coal Handling Plant. From the
Bunker, this coal is fed into the mill through Raw Coal Feeder. The feed to the coal mill can be
controlled by regulating the speed of the Feeder. In plant total 24 Bowl mills are used each unit
used only 4 Bowl mills and 2 Bowl Mills are stand by position So, at one time 4 Bowl Mills are
Running Condition.

Type of Pulvrziser:

BOWL MILL : XRP-803,

Coal pulverizing capacity : 36.9 Ton/hr,
Motor : 340KW, 6.6KV

19
PARTS OF BOWL MILL

1) MILL BASE:
This is the lowest position of mill and it contains mill drive system i.e.
worm shaft, oil cooler as main parts. The gear Housing is always filled with lubrication oil before
the pulverize is put into operation. Level of the oil can be checked from the oil level gauge
provided on the mill base. Correct level is indicated only while the mill is idle. For cooling the oil
while mill is in operation, Tube type water cooler have been installed in the Gear Housing.

2) MILL SIDE:
This portion is just above the mill base and it contains mill side liners,
Scrapper assembly and Tramp iron spout discharge arrangement & vane wheel assembly. Heated
primary air enters the mill side housing below the Bowl. Any tramp iron, stone etc. drop in this
portion and are scrapped to the tramp iron discharge spout for empting in the Mill Reject Belt.

3) MILL OUTLET ASSEMBLY:

This portion contains classifier venture and deflector
regulator. Mill discharge valve assembly is connected at the top of this portion from where the
pulverized coal is agent to each of four coal nozzles at one elevation.

4) SEPARATOR BODY ASSEMBLY:

This portion is just above the mill side
housing and this is the portion where coal is pulverized. Main parts of this assembly are Bowl,
Journal assembly, Grinding Roll Assembly Bull ring segments, liners, Inner cone, classifier
assembly, Separator body liner assembly and center feed pipe. The Grinding Rolls do not rotate if
the miss is empty. When the raw coal from centre feed pipe comes in between the Grinding Rolls
and revolving bowl, it causes the rolls to turn and thus, the coal gets pulverized.

20
Fig. 16.12 Separator

Fig. 7.1 BOWL MILL

21
 MILL LUBRICATION

In coal pulverized system bowl mill is used to pulverize the coal. In this system due to the
friction in the mating parts starts erodes. To eliminate that effect the lubricatin is done. It is done in
the self rotating roller and under the bowl plate, bearings are also provided here to eliminate the .

Fig. 7.2 MILL LUBRICATION SYS.

22
 COAL TRANSFER SYSTEM TO BOILER

Fig. 7.3 COAL PATH TO BOILER

PARTS OF COAL TRASPOTATION TO THE BOILER:
 COAL BUNKER
 COAL FEEDER
 BOWL MILL
 TRANSFER PIPE
 FURNANCE

23
 DM PLANT

RAW WATER TREATMENT

The quality of water needed for industries depends upon its intended use. Ultra high purity Water is
required for high pressure steam generating system.

The water impurities can result in serious operating problems caused by deposit formation.
Corrosion of metal. Foaming in steam generating & micro biological foiling & wood deterioration
in cooling water system.

The average raw water quality at GHTP Lehra Mohabbat is as below:

Designed Actual
Turbidity 100ppm 30-70ppm
Ph 7.3 to 8.3 8-8.5
Alkalinity 100ppm as Ca co3 50-80ppm
Chlorides 30ppm as Ca co3 20-30ppm
Total Hardness 120ppm as Ca co3 70-12ppm
Sulphates 134ppm as Ca co3 50-70ppm
Calcium Hardness 80ppm as Ca co3 50-80ppm
Magnesium Hardness 40ppm as Ca co3 20-40ppm
Dissolved Silica 5ppm as Ca co3 3-5ppm
Colloidal Silica 1ppm 1-2ppm
Total dissolved Solids as such 200ppm 150-200ppm
Total suspended Solids 50ppm 30-50ppm

24
 Water Treatment Consists of:

1. CLARIFICATION:
It is a process applied to surface water for removal of suspended
solids, finer solids which appears as turbidity, color & other colloidal materials. These processes
incorporate coagulation flocculation & sedimentation each is a distinct procedure which mandate
certain requirements to ensure the desired results.

At GHTP Lehra Mohabbat we are having one no. clarifier having capacity 3800 M3/hr for
cooling water system and a 180 M3/hr sludge blanket for the operation of D.M. Plant.

Fig. 8.1 CLARIFIER

25
 DM PLANT

In GHTP Lehra Mohabbat only one DM Plant is used for raw water convert the DM Water and this
dm water is used in boiler because the dm water is very pure and this water PH quality is very
suitable for steam. The dm water is heated up in less time and boiler compute is free from
corrosion.

Fig. 8.2 DM PLANT OVER VIEW

26
% make up of DM water by GHTP

27
 BOILER FEED PUMP

Each pump set consists of a FA IB 56 Booster Pump, directly drive from one
end of the shaft of an electrical driving motor, and a “FK 6D 30” Boiler Feed Pump driven from
opposite end of the motor shaft through a variable speed Turbo Coupling type R16K.1. The drive
is transmitted in each cause through a spacer type flexible coupling each coupling being enclosed
in a split fabrication guard.

Fig. 9.1 BOILER FEED PUMP

28
 BOILER FEED PUMP:

A boiler feed water pump is a FK6D30 type of pump used to

pump feed water into a steam boiler. The water may be freshly supplied or returning condensate
produced as a result of the condensation of the steam produced by the boiler. These pumps are
normally high pressure units that use suction from a condensate return system and can be of the
centrifugal pump type or positive displacement type.

The FK6D30 TYPE Boiler Feed Pump is a six stage Horizontal centrifugal pump of
barrel casing design. Inter stage tap off is provide for PRDS and Reheater spray from 2nd stage.

Fig. 9.2 GENREL LEYOUT OF FEED PUMP

29
 TECHANICAL DATA OF BOILER FEED PUMP

Pump type : FK6d30

No. of stages : 6 (Six)
Direction of rotation : Antic lock - wise
(Viewed from driven end)
Liquid pumped : Boiler Feed Water
Suction temperature : 161.3oC
Sp. Wt. At suct. Temp. : 906.1 Kg/cum
Design flow : 475 cum/hr
Differential head : 2105 mlc
Mini, RC flow : 110 cum/hr
Efficiency : 82 %
Speed : 5145 rpm
Input power : 3008.8 Kw
Inter stage flow : 55.2 cum/hr

Thrust bearing:
Manufacturer : Glacier Metal Co., U.K.
Type : Double thrust, CK range
Size : 8159/2KP-2KP

Coupling between Hydraulic coupling & pump:

Manufacturer : Bharat Forge Ltd., India
Type : HBS 1000-8X

Coupling between Hydraulic coupling & Motor:

Manufacturer Type : Bharat Forge Ltd., India
Type : HBS 3600-8

Hydraulic coupling:
Manufacturer : Voith Turbo GMBH and Co.
Type : R 16 K. 1

30
Drive motor:
Manufacturer : B.H.E.L.
Type : SCIM
Rating : 4000 kW
Speed : 1485 rpm
Electrical Supply : 6.6 kV, 3-phase, 50 Hz

BOILER FEED BOOSTER PUMP

The Booster is a single stage horizontal axial split casing type having the suction and discharge
branches on the casing bottom half thus allowing the pump internals to be removed without
disturbing the suction and discharge pipe work of the alignment between the pump and motor.

The pump shaft is sealed at the drive end and non drive end by mechanical seals which are flushed
by a supply of clarified water. The rotating assembly is supported by plain white metal lined
journal bearing and axially located by a Glacier double tilting pad thrust bearing

 Application:
Booster pumps are used to cater the requirements of Boiler feed pumps
suction. They are driven by the main BFP drive motor which has shaft extensions on both ends.

 Design features:

 Horizontal single stage construction

 Axially split casing (volute type)
 Double suction impeller
 Low NPSH requirement
 Tilting pad type thrust bearing
 Mechanical seals

31
 TECHANICAL DATA OF BOOSTER PUMP

1. Type of pump : Single stage, volute

type with Horizontal
split casing
2. No. of pumps required per each turbo set : 2+1
3. Rated speed : 1483 rpm
4. Design flow : 475 cub. M/hr
5. Head developed : 103 mlc
6. Efficiency : 78 %
7. Input power : 146 kw
8. Direction of rotation of the pump : Antic lock wise
(Viewed from motor
side)
9. Type of journal bearings : Babbitt lined bush
bearing
10. No. of bearings : 2 journal + 1 thrust
bearing
11. Type of lubrication : Forced Oil lubrication
12. Suction Temp. : 160.8o C
13. NPSH required : 6.00 mlc
14. Type of coupling : Flexible coupling of
diaphragm design
15. Mechanical Seal:
Type : 4.25” PTO / 503
Manufacturer : Duramet allic / Sealol

16. Flexible coupling:

Type : HB4-140X
Manufacturer : Bhart Forge Ltd.

17. Thrust bearing:

Type : 8112/2KP-2KP
Manufacturer : M/S Glacier

Boiler feed pump takes supply of water from Deaerator and supplies it to Boiler Drum against the
positive pressure in the drum, the supply of water is regulated by v/v’s feed manifold station and
scoop tube of the pump.

Feed control suction has

i. Main line (100%) Scoop tube variation is from
ii.Bypass line (100%) 30% to 100%
iii.Low load line (30%)

32
 STEAM GENERATOR

The steam generator is of radiant, reheat, natural circulation single drum, dry bottom and semi-
outdoor type unit, designed for firing coal as the principal fuel and the HFO oil firing capacity is
equivalent to 22.5% boiler MCR. 4LDO burners are capable for 7.5% boiler MCR heat input. AS
per layout arrangement the mills are located between Boiler and ESPs. The complete furnace
section is of fusion welded wall type arranged as a gas and pressure tight envelope. The extended
side wall section is covered with water cooled fin welded walls. The maximum fuel gas velocity in
the pressure part system is limited to 10 – 12 m/sec. At 100% boiler MCR load.

Fig. 10.1 STEAM GENRATOR

33
 All the headers in the pressure part system are provided with necessary hand holes and hand
holes plate’s arrangement. All headers are located outside the gas path, except for the economizer
inlet and intermediate headers which are located in the low gas temperature section in 2nd pass. The
complete pressure parts are suspended from the boiler structural steel roof sections and arranged
for free expansion downward.

Fig. 10.2 STEAM GENRETOR DETAIL DEGINE

34
 BOILER
Boiler used in the thermal power plant is water tube, internal combustion, coal based. The height of
boiler site at GHTP is STAGE-1 is near about 56m and STAGE-2 is 61m. the steam dum is located
at the hight of 54m at STAGE-1 and 59m at STAGE-2.

35
  SUPERHEATER :
Most of the modern boilers are having super heater and reheater
arrangement. Superheater is a component of a steam-generating unit in which steam, after it has
left the boiler drum, is heated above its saturation temperature. The amount of superheat added to
the steam is influenced by the location, arrangement, and amount of super heater surface installed,
as well as the rating of the boiler. The super heater may consist of one or more stages of tube banks
arranged to effectively transfer heat from the products of combustion. Super heaters are classified
as convection, radiant or combination of these.

 REHEATER :
Some of the heat of superheated steam is used to rotate the turbine where it
loses some of its energy. Reheater is also steam boiler component in which heat is added to this
intermediate-pressure steam, which has given up some of its energy in expansion through the high-
pressure turbine. The steam after reheating is used to rotate the second steam turbine where the
heat is converted to mechanical energy. This mechanical energy is used to run the alternator, which
is coupled to turbine, there by generating electrical energy.

36
  ECONOMISER :
Flue gases coming out of the boiler carry lot of heat. Function of
economiser is to recover some of the heat from the heat carried away in the flue gases up the
chimney and utilize for heating the feed water to the boiler. It is placed in the passage of flue gases
in between the exit from the boiler and the entry to the chimney. The use of economiser results in
saving in coal consumption, increase in steaming rate and high boiler efficiency but needs extra
investment and increase in maintenance costs and floor area required for the plant. This is used in
all modern plants. In this a large number of small diameter thin walled tubes are placed between
two headers. Feed water enters the tube through one header and leaves through the other. The flue
gases flow out side the tubes usually in counter flow.

 AIR PREHEATER :
The remaining heat of flue gases is utilized by air preheater. It is
a device used in steam boilers to transfer heat from the flue gases to the combustion air before the
air enters the furnace. Also known as air heater; air-heating system. It is not shown in the lay out.
But it is kept at a place near by where the air enters in to the boiler.

The purpose of the air preheater is to recover the heat from the flue gas from the boiler to
improve boiler efficiency by burning warm air which increases combustion efficiency, and
reducing useful heat lost from the flue.

 DEAERATOR :
A steam generating boiler requires that the boiler feed water should be
devoid of air and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of
the metal.

Generally, power stations use a Deaerator to provide for the removal of air and other
dissolved gases from the boiler feed water. A Deaerator typically includes a vertical, domed
deaeration section mounted on top of a horizontal cylindrical vessel which serves as the deaerated
boiler feed water storage tank.

There are many different designs for a Deaerator and the designs will vary from one
manufacturer to another. The adjacent diagram depicts a typical conventional Deaerator. If
operated properly, most Deaerator manufacturers will guarantee that oxygen in the deaerated water
will not exceed 7 ppb by weight (0.005 cm³/L).

37
Fig. 10.3 DEAERATOR

38
 TECHANICAL DATA OF BOILER

1. Furnace Wall System O.D. No. Types of Joint

i. Front Wall 63.5mm 181 Fusion
ii. Rear Wall 63.5mm 181 Fusion
iii. Side Wall (per side) 63.5mm 131 Fusion
iv. Extended Wall (per side) 63.5mm 26 Fin welded

2. Furnace Width 13868 mm

3. Furnace 10592 mm
4. Furnace volume (Approx.) 5200 m3
5. Furnace area effective projected 2100 m2

6. Reheater Front Rear

i. No. of assemblies 59 59
ii. No. of element/assembly 6 6
iii. Tube O.D. 54×4mm 54×3.6mm

60.3×4mm 44.5×4mm

iv. Material SA213-T11 ( ½ Cr MO )

SA213-T22 ( 2 ¼ Cr MO )
SA209 T-1 ( ½ MO )
SA 213 T-91

FILLING CAPACITY
Boiler Drum : 35 Ton
Economiser : 25 Ton
Water Wall : 130 Ton
Super Heaters : 95 Ton
Reheater : 50 Ton
Water required for normal light up : 190 Ton
For Hydrostatic test : 335 Ton

39
SUPER HEATER
Description O.D. No. Type

i. Furnace Roof 51.0mm 120 Fin welded

ii. Back pass Roof 44.5mm 120 “
iii. Back pass front 44.5mm 98 “
iv. Back pass Rear 44.5mm 120/9(Upper/Lower) “
v. Back pass Side(per side) 44.5mm 66 “
vi. Back pass extended(per side) 44.5mm 17 “

vii. Material for above Carbon Steel (5a210 G-C), SA209T-1(½ MO)
SA 210 Gr. Carbon steel

ECONOMIER
i. No. of assemblies 145 No.
ii. O.D. 44.5 m Material – Carbon steel

DRUM I.D. 1778 mm

BOILER PARAMETERS

1. Superheater outlet Steam flow : 690 T/Hr (MCR)

2. Steam Pressure at SH. Outlet : 155 Kg/Cm2(G)
3. Steam temperature at SH. Outlet : 540º C
4. Reheater outlet steam flow : 597.5 T/Hr
5. Steam pressure at RH. Inlet : 37.6 Kg/Cm2(G)
6. Steam pressure at RH. Outlet : 36.1 Kg/ Cm2(G)
7. Steam temperature at RH. Inlet : 342o C
8. Steam temperature at RH. Outlet : 540o C
9. Feed water temperature entering economiser : 243o C
10. Ambient air temperature : 40o C

40
 BOILER AIR AND GAS SCHEME:

Air flow is required in boiler mainly for two purposes:

1. For the combustion of fuel in furnace this air is called secondary air.
2. For drying and transportation of pulverized coal to the furnace from the mill called Primary
Air Fan.

Secondary Air:
Secondary air is supplied by two forces draft fans are given below:

FORCED DRAUGHT (FD) FAN:

Each unit shall have two forced draught fans. The fans
draw warm air from the top of the boiler house through large air heaters becoming the primary and
secondary air used for the boiler combustion process. The air heater warms the incoming air by
transferring heat energy from the outgoing flue gases

Fig. 11.1

41
INDUCED DRAUGHT (ID) FAN:
Two induced draught fans draw gases out of the boiler.
The gas has already passed through the air heaters and precipitators before it has reached these
fans. The heat from the flue gases or smoke is used in the air heaters to heat up the primary and
secondary air

Fig. 11.2

TECHANICAL DATA

1. Type of operation : Continuous

2. No. of fans : 3 per boiler(2running, 1 stand by)
3. Type of operation : Fuel Gas Exhaust
4. Orientation : Horizontal
5. Capacity : 230 M3/sec
6. Total head developed : 350 mm
7. Temp. of medium : 150o C
8. Speed : 990 rpm
9. Motor
Power : 1300 kW
Electric supply : 6.6 kV
Speed : 990 rpm

42
PRIMARY AIR FAN:
Each unit shall have two primary air fans. Air to blow the coal from the
mill to the boiler, called the primary air, is supplied by a large fan driven by a variable speed
motor. When mixed with a stream of air the powdered coal behaves more like a gas than a solid.
Primary air does two jobs – heating the coal powder and secondly lifting it into the furnace through
pipelines

PARTS OF PA FAN:
1. Stator
2. Rotor
3. Coupling
4. Drive
5. Lop system

TECHANICAL DATA
1. Type of operation : Continuous
2. No. of Fans : Two per boiler
3. Medium handled : Atmospheric
4. Orientation : Vertical suction bottom
horizontal delivery
5. Fan Capacity : 70 M3/sec
6. Total head developed : 1210 mm
7. Speed : 1480 rpm
8. Temperature : 50o C
9. Motor
Power : 1250 kW
Electric supply : 6.6 kV
Speed : 1480 rpm

Boiler light-up
Boiler light-up means the starting of the boiler or flaming the furnace. There are two
types of boiler light up sys.

 Cold light-up
 Hot light-up

 Cold light-up
When the boiler starts up takes at atm. temperature. At this time first L.D.O(light diesel
oil) is given to the furnace with high temp. steam. The reason to give the steam is that because at
atm. Temp. the state of L.D.O. is hard. so to liquefy the oil steam is given to it. The oil is send to
the furnace with the help if oil guns. Near the tip of the oil gun a lighter or spark plug is provided.
When the oil is fed to the furnace then lighter is ignited and oil catches the fire and starts burning.

43
After proper burning the H.F.O.(Hot furnace oil) is fed to the furnace and H.F.O. is stopped. After
that the pulverized coal is fed to the furnace and combustion starts.

 Hot light-up
When the boiler start up takes place after a trip case that time the temp. of the boiler
is sufficient to skip the first step of H.F.O. and directly L.D.O. is used to light-up the boiler.

• Spark plug provides the initial ignition. Light Diesel oil is then fed to the burner and it
catches fire
• This is followed by heavy furnace oil (HFO)
• Once a stable flame is established the coal/air mix is blown through the burner where it
lights spontaneously
• The oil are then shut off. Burner position, coal flow and air flow are controlled to achieve
desired output of temperature, pressure and flow and hence the electricity
• At full output 4,000 MW power station can burn more than 50,000 tons of coal a day

44
 STEAM TURBINE

In GHTP Lehre Mohabbat 210MW and 250MW single shaft reaction turbines, Tandem Coupling
3000 R.P.M. double flow exhaust, reheat type with initial parameters of 150 Kg/sq.cm. and 535oC.
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and
converts it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in
1884.

Fig. 12.1 STEAM TURBINE

The first device that may be classified as a steam turbine was little more than a toy, the
classic Aeolipile, described in the 1st century by Hero of Alexandria in Roman Egypt. A thousand
years later, a steam turbine with practical applications was invented in 1551 by Taqi al-Din in
Ottoman Egypt, who described it as a prime mover for rotating a spit. Another steam turbine
device was created by Italian Giovanni Branca in year 1629.

A steam turbine is a mechanical device that extracts thermal energy from pressurized
steam, and converts it into useful mechanical work.

It has almost completely replaced the reciprocating piston steam engine primarily because
of its greater thermal efficiency and higher power-to-weight ratio. Also, because the turbine
generates rotary motion, it is particularly suited to be used to drive an electrical generator; about

45
80% of all electric generation in the world is by use of steam turbines. — It doesn't require a
linkage mechanism to convert reciprocating to rotary motion.

The steam turbine is a form of heat engine that derives much of its improvement in thermo
dynamic efficiency through the use of multiple stages in the expansion of the steam (as opposed to
the one stage in the Watt engine), which results in a closer approach to the ideal reversible process.

a) High Pressure Turbine:

High pressure steam at 560°C and 160ksc pressure
passes through the high pressure turbine. The exhaust steam from this section is returned to the
boiler for reheating before being used in the next section of the turbine set. The blades in the high
pressure turbine are the smallest of all the turbine blades; this is because the incoming steam has
very high energy and occupies a low volume. The blades are fixed to a shaft and as the steam hits
the blades it causes the shaft to rotate

b) Intermediate Pressure Turbine:

On leaving the boiler Reheater, steam enters
the intermediate pressure turbine at 560°C and 40 ksc pressure (1 ksc = 14.22 psi ). From here the
steam goes straight to the next section of the turbine set. The steam has expanded and has less
energy when it enters this section, so here the turbine blades are bigger than those in the high
pressure turbine. The blades are fixed to a shaft and as the steam hits the blades it causes the shaft
to rotate

c) Low Pressure Turbine:

From the intermediate pressure turbines, the steam
continues its expansion in the three low pressure turbines. The steam entering the turbines is at
300°C and 6 ksc pressure. To get the most work out of the steam, exhaust pressure is kept very
low, just 50 mille-bar above a complete vacuum. The tip speed of the largest blades with the shaft
spinning at 3,000 revolutions per minute is 2,000 kmph

Boiler Reheater:
• After expanding through the high pressure turbine the exhaust steam is returned to the
boiler at 360°C and 40 ksc pressure for reheating before being used in the intermediate
pressure turbine

• The Reheater reheats the steam from a temperature of 360°C back to 560°C

46
TECHANICAL DATA

1. Make : B.H.E.L.
2. Type of turbine : Horizontal type
3. No. of Cylinder : Three (3)
4. Steam is used : Dry Steam
5. Coolant : Water & Hydrogen
6. Gas Pressure : 3.5Kg/Cm Sq

STAGE-I STAGE-II
i. Rated out put 210 MW 250 MW
ii. Rated Speed 3000 R.P.M. 3000 R.P.M.
iii. Inlet Steam Pressure 150 Kg/cm2 150 Kg/cm2
iv. Inlet Steam Temperature 535o C 535o C

Fig. 12.2Modern steam turbine generator for a coal fired steam plant

47
 Fig.12.3 HP AND IP CASING

CONDENSER

Surface condenser is the commonly used term for a water-cooled shell and tube heat
exchanger installed on the exhaust steam from the steam turbines that drive the electrical
generators in thermal power plants. These surface condensers are heat exchangers which convert
steam from its gaseous to its liquid state at a pressure below atmospheric pressure.

 PURPOSE:
In thermal power plants, the primary purpose of a surface condenser is
to condense the exhaust steam from a steam turbine at as low a pressure as possible and to obtain
pure water (referred to as steam condensate) so that it may be reused in the steam
generator or boiler as boiler feed water.

The steam turbine itself is a device to convert the heat in steam to mechanical work. The difference
between the enthalpy of the inlet steam to a turbine and the enthalpy of the exhaust steam
represents the heat which is converted to mechanical work. Therefore, the larger the enthalpy
difference between inlet steam and exhaust steam, the higher is the amount of work delivered by
the turbine. Condensing the exhaust steam of a turbine at a pressure below atmospheric pressure
increases that enthalpy difference and therefore increases the work output of turbine. The water-
cooled surface condensers used on the steam turbine exhausts in large power plants usually operate
at an absolute pressure of about 35 to 40 mmHg which is far below the typical atmospheric
pressure of 760 mmHg.

48
Most of the heat liberated by condensing the exhaust steam is transferred to and carried away by
the cooling medium (water or air) used by the surface condenser.

Fig. 13.2 Condenser

a) SHELL:
The shell is the condenser's outermost body and contains the heat exchanger tubes.
The shell is fabricated from carbon steel plates and is stiffened as needed to provide rigidity for the
shell. When required by the selected design, intermediate plates are installed to serve as baffle
plates that provide the desired flow path of the condensing steam. The plates also provide support
that help prevent sagging of long tube lengths.

At the bottom of the shell, where the condensate collects, an outlet is installed. In some designs, a
sump (often referred to as the hot well) is provided. Condensate is pumped from the outlet or the
hot well for reuse as boiler feed water.

For most water-cooled surface condensers, the shell is under vacuum during normal operating
conditions.

49
 b) VACUUM SYSTEM:

13.3 VACCUM SYSTEM

Schematic diagram of a typical injector or ejector. For a steam-jet ejector, the motive fluid is
steam.

The internal vacuum in the shell of a water-cooled surface condenser is most commonly
supplied by and maintained by an external steam-jet ejector system. Such an ejector system uses
steam as the motive fluid to remove any non-condensable gases that may be present in the surface
condenser.

The Venturi effect, which is a particular case of Bernoulli's equation, applies to the
operation of steam-jet ejectors.

Motor driven mechanical vacuum pumps, such as liquid ring type vacuum pumps, are also
used for this service

c) TUBE SHEETS:
At each end of the shell, a steel sheet of sufficient thickness is
provided, with holes for the exchanger tubes to be inserted. The inlet end of each tube is also bell
mouthed for streamlined entry of water. This is to avoid eddies at the tube inlets giving rise
to erosion, and to reduce flow friction. To take care of length-wise expansion of the tubes, some
designs may have expansion joints (pleated steel bellows) between the shell and the tube sheets
allowing the latter to move longitudinally.

50
 d) TUBES:
Generally the tubes are made of stainless steel, copper alloys such
as brass or bronze, cupro nickel, or titanium depending on various criteria. The tube lengths range
up to about 55 ft (17 m) for modern power plants, depending on the size of the condenser. The
outer diameter of the condenser tubes typically ranges from 3/4 inch (19 mm) to 1-1/4 inch (32
mm), based on condenser cooling water friction considerations and overall condenser size.

e) COOLING WATER INLET AND OUTLET:

Each end of the condenser shell is
closed by a box cover referred to as a water box, connected to the tube sheet or condenser shell by
a flange. The water box is usually provided with manholes on hinged covers to allow periodic
inspection and cleaning.

The inlet and outlet water boxes also have flanges for connecting to the inlet and outlet
water lines. They also have small, valve air vents at the top of the boxes and valve drains at the
bottom of the boxes for use during periodic maintenance shutdowns.

CONTROL VALVE

Control valves are valves used within industrial plants and elsewhere to control operating
conditions such as pressure, temperature, liquid level and flow rate by fully or partially opening or
closing in response to signals received from controllers that compare a "set point" to a "process
variable" whose value is provided by independent sensors that monitor changes in such conditions.

Control valves are an integral part of the hundreds (or even thousands) of control loops networked
together in industrial plants to produce their various end products.

A control valve is part of an assembly that typically includes a valve body (and its internal parts),
an actuator to provide the motive power for opening and closing the valve, and a variety of
additional accessories such as positioners, transducers, manual operators and limit switches. The
motive power provided by the actuators may be electrical, hydraulic or pneumatic.

51
 Fig. 13.4 SCHEMATIC DIAGRAM OF CONVENTIONAL CONTROL
VALVE WITH A PNEUMATIC ACTUATOR

Applications:

 Control valves are used in industries such as petroleum refining, chemical and
petrochemical manufacturing, nuclear power plants and fossil fuel power plants, natural gas
processing and many others.

 In such industries, control valves are an essential component of the systems used to control
important operational parameters like pressure, temperature, liquid levels and flow rates.
 Pressure control valves may be used to reduce liquid or gas pressures or they may be used
to maintain a back-pressure (i.e., a pressure upstream of the valve). They may also be used
to maintain a pressure difference between two points in a process.
 Temperature control valves are used to maintain liquid or gas temperatures within process
vessels or to control the heat transfer within heat exchangers and process heaters or
furnaces.
 Level control valves are used to maintain liquid levels within a desired range in process
vessels or tanks. In some cases, they may also be used to maintain levels of solid particles.
 Flow control valves are used to control the volumetric or mass flow rate of liquids and
gases. They may also be used to maintain a desired ratio between two flows, in which case
they are part of what is called a flow ratio controller.

52
 POWER GENRETOR

Generation is the process of generating electric energy from other forms of energy.
Electromagnetic induction, where an electrical generator, dynamo or alternator transforms
kinetic energy (energy of motion) into electricity, this is most used form for generating
electricity, it is based on Faraday's law, can be experimented by simply rotating a magnet
within closed loop of a conducting material (e.g. Copp

Fig. 13.1 POWER GENERATOR ASSEMBELED WITH TERBINE

The power generated by the generator of STAGE-1 is in 15.75 kW and then it is Sent
to the transformer here it is step-up to the 220kW. In STAGE-2 power generated by the generator
is 16.5 and it is step-up to the 250kW. After that the electricity is send to the grids of different
cities.

53
 COOLING TOWERS

In GHTP Lehre Mohabbat four cooling towers are used. The condensate (water) formed in the
condenser after condensation is initially at high temperature. This hot water is passed to cooling
towers. It is a tower- or building-like device in which atmospheric air (the heat receiver) circulates
in direct or indirect contact with warmer water (the heat source) and the water is thereby cooled. A
cooling tower may serve as the heat sink in a conventional thermodynamic process, such as
refrigeration or steam power generation, and when it is convenient or desirable to make final heat
rejection to atmospheric air. Water, acting as the heat-transfer fluid, gives up heat to atmospheric
air, and thus cooled, is re circulated through the system, affording economical operation of the
process. The length of cooling tower is maximum 350 meter to 450 meter.In GHTP the Counter
flow type cooling tower are placed. In this type of cooling tower the air flow is directly opposite to
the water flow (see diagram below). Air flow first enters an open area beneath the fill media and is
then drawn up vertically. The water is sprayed through pressurized nozzles and flows downward
through the fill, opposite to the air flow.

Fig. 14.1 WORKING OF COOLING TOWER

54
Fig. 14.2 COOLING TOWER AT GHTP LEHRA MOHABBAT

55
 COOLING WATER SYSTEM

The total cooling water requirement for running two number units (210 MW each) at Guru
Hargobind Thermal Plant , Lehra Mohabat is supplied by the intake pump house. The raw water is
taken from the Sir hind canal distributor running just nearby the plant area and stored in the storage
pond. The pond act as water reservoir during the period the canal is under shut down for
maintenance purpose or otherwise. Normally, turbidity of raw water is between 150-200 rpm,
which increases to 400 – 500 ppm during rainy season. In order to destroy algae and bacteria in the
raw water, chlorination at the intake pump house is done as per requirement. The water from pond
is taken to the clarifier with the pumps installed in the intake pump house.

o CLARIFIERS:
The basic purpose of clarifier is to remove or to precipitate the
undeserved impurities present in raw water which coagulates by putting alum and settle down at
the bottom of clarifiers in the form of sludge which is further removed with the help of desludging
valves provided for the purpose .The quantity of alum is regulated depending upon the turbidity of
raw water.

The circulating water required for the C.W Pumps Is Prepared In the Clarifier NO.1. One is
common service clarifier (capacity 3800 m3 / hr.). The water from the clarifiers is transferred to the
clear well Of D.M. plant the clarified water from the clear wells is used for the following different
purposes:-

1.) For makeup of the circulating water in the C.W Pump.

2.) For various services in the plant
3.) For fire fighting purpose.
4.) The water from main clarifier no.1 comes to sludge blanket where further alum dosing is
done and this water is used to prepare D.M. water in D.M. plant.

o Cooling water system:

There are 6 No. pumps in the C.W. pump house for both the
units, three pumps for each unit. Out of three pumps, 2 No. pumps for each unit having capacity
50% each are run and one number pumps acts as standby. The piping of the stand by pumps has
been done in such a manner that the standby pump can be used for the other unit also .The
particulars of the C.W. pumps installed at G.H.T.P. Lehra Mohabat are as under :-

Manufacturer : M/s, Joyti Ltd.

Type : Wet pit, mixed flow, vertical non extractable
pump directly coupled with
Electric motor drive.

56
 Design of the glands has been improved that during start up, minimum water passes along
with the shaft. Moreover, the electrical motor of the pump has been kept on a separate floor i.e.
sufficient partition is provided so that water does not fall on the motor.

o Auxiliaries cooling system at GHTP Lehra Mohabat:

Auxiliaries cooling system is divided into two parts:-

1. Turbine auxiliaries cooling system.

2. Boiler auxiliaries cooling system.
The source of turbine auxiliaries cooling system is turbine auxiliary C.W. pumps (TACW
Pumps) and for boiler auxiliary cooling system, it is boiler auxiliary C.W. pumps.

o The TACV Pump:

There are two no. TACW pumps one pumps is for 100% capacity and
other is stand by. These pumps take suction from up stream of condenser and the after
routing the water from various coolers; discharge it into hot water tunnel. The particulars of
these pumps are as under:-

Capacity : 800m3 hrs.

Head : 35 MWC
Motor rating : 110 KW 415 V

The cooling water requirement and other features of turbine aide cooling as under:

o Generator Stator Winding Cooler:

Water requirement : 220 m3/ hr

Water requirement : DM water is circulated in stator bars
And this hot DM water in stator water cooler by
clear water.

H2 coolers : 350 m3 / hr

Turbine oil coolers : 3625 m3 / hr

Seal oil coolers : 130 m3 / hr

57
 HYDROGEN GAS PLANT

Hydrogen Gas at GHTP Lehra Mohabbat is used the Rotor. The daily consumption of Hydrogen
gas is 3 to 4 cylinder approximately which is …….Nm3. The Hydrogen Plant is designed to
produce hydrogen gas at the rate of 10 Nm3/hr. and Oxygen Gas at the rate of 5 Nm3/hr. the
oxygen gas generated is vented to the atmosphere.

PROCESS DESCRIPTION

 ELECTROLYSERS :

Hydrogen and oxygen gas is produce by feeding direct current to

electrolytic cells. There are 14 cells arranged in two banks of 7 cells each in series. A steady
current of 2000 Amps. Is passed gradually through the cells. The electrolyte consists of DM water
and NaOH of 20% concentration. NaOH is added to improve the efficiency of electrolysis
operation and to minimize the electrical resistance between electrodes. When DC current Flows
DM water gets electrolyzed to give Hydrogen Gas and Oxygen Gas The reaction formula is as
below:
2H2O + Energy = 2H2 + O2

From these headers gases flow to Gas Washing Tanks (GWT) and bubble through the DM water.
Which scrubs the generated gas and strips off carrying over of the caustic. The purity of the
Hydrogen Gas is measured by means of Thermal Conductivity Analyzer (TCA). When it is
ascertained that Hydrogen Gas has acquired the desired purity (min 99.0%), only then hydrogen is
allowed to be diverted in the low Pressure Gas Holder. Hydrogen Gas Storage Tank. Till this purity
is achieved the Hydrogen Gas is vented off. By product Oxygen Gas is always vented to
atmosphere.

 LOW PRESSURE GAS HOLDER (LPGH) :

The Hydrogen Gas Stored in a Low

pressure floating roof type gas holder. Water seal has been providing between two tanks to check
gas leakage. The floating roof is balanced by counter weights.

58
  HYDROGEN GAS COMPRESSER :

Hydrogen Gas Compression is done by reciproting

compressor. The compressors compress the hydrogen gas from 0 to 50 mmwc to 150 kg/cm2. The
hydrogen gas is sucked from the low pressure gas holder via knock-out drum having demister pads
for knocking out water droplets and other undesirable particles. The compressed gas is passed
through filters at a pressure of 150 kg/cm2.

 PURIFIER AND DRYING UNIT :

Hydrogen Gas is purified by removing the traces of

Oxygen in the Deoxo purifier by passing the same through a bed of palladium catalyst. In the
presence of this catalyst, hydrogen and oxygen traces react to form water vapors. The reaction is
exothermic and the heat so produced raises the temperature of the gas. Hence the gas coming out of
the purifier is cooled and then passed through the gas dryer. Purified gas is passed through the twin
bed regenerative dryer unit to absorb moisture contained in the gas to give atmospheric dew point
of -60 deg. C.

 HYDROGEN STORAGE CYLINDERS THROUGH MANIFOLDS :

From dryer the gas

is analyzed for the dew point and hydrogen purity. After confirmation of Hydrogen Purity of
99.9% and dew point -60 deg. C, the gas is stored in cylinders through hydrogen filling manifolds
at 150 kg/cm2

PRESTART-UP CHECK LIST

1. Electrolyte Level in Cell : up to 100 mm from

top
2. Specific Gravity of electrolyte : 1.18 to 1.25
3. Temperature of electrolyte : Ambient
4. Vent valve at GWT : Open
5. Vent line of GWT o2 : Open
6. Delivery valve for H2 to LPGH : Closed
7. DM Water level in GWT : 100 mm
8. Level of DM water in DM water tank : Adequate
9. Valve from DM water tank to GWT : Open

59
10. Rectifier
a) OG Switch from MCC to Rectifier : ON
b) Rectifier incoming switch : OFF
c) DC out put voltage of Rectifier : 0
d) DC out put Current : 0

11. Line up Purifier / Cooler / Drier

12. All measuring instruments should be in order
13. Hydrogen Gas Manifolds
a) Check All Valves and line up
b) Safety valve should be in order
c) Shut off valve should be In Open position

Water : Ensure DM water supply having conductivity less than One micron

SPECIFICATION

 HYDROGEN GAS INLET CONDITION:

1. Service : H2 Gas
2. Flow : 12 Nm2/Hr.
3. O2 Content : 0.1 - 0.2%
4. H2 Content : Balance
5. Pressure at inlet : 125-150 kg/cm2g

 HYDROGEN GAS OUTLET CONDITION:

1. Flow : 12 Nm2/Hr.
2. Moisture : (-) 70oc Dew
3. Pressure : 125-110 kg/cm2g
4. O2 Content : 5 ppm (Max)

60
 COMPRESSORS HOUSE

In GHTP Lehra Mohabbat 4 Compressor Houses. In compressor house two types compressors are
used INSTRUMENT COMPRESSOR and SERVICE AIR COMPRESSOR. Principal of a BOP
Compressor. Two cylinders are positioned on either side of crankcase facing each other being
driven by same Crank shaft with the two cranks at 180o the reciprocating mechanism in the two
cylinders will always have movements exactly opposed to each other thus imparting perfect
dynamic balance into the system.

The Balanced opposed piston compressors are either single stage design where input
pressure for both the cylinder are same P1 (atmospheric pressure) & so also the output pressures P2
or two stage design where the output pressure of a two stage compressor P3 will be higher than that
of a corresponding single stage compressor.

 Features:
1. Minimum Vibration
2. Lighter Foundation
3. Higher efficiency
4. Maximum reliability
5. Control and safety Device
6. Easy installation

Following are two types of compressors are used in GHTP Lehra Mohabbat:
a) Instrument air compressors
b) Service air compressors

a) INSTRUMENT COMPRESSOR:
The instrument compressors are very important
compressor because all the instruments, valves are operated by this compressor. Each unit have 2
instrument compressors one is running and second is stand by condition when running compressor
stop then in 5min second instrument compressor is start. When this compressor is stop working
then under 5min plant is trip all the instrument stop working. This compressor air is cool and
compressed air pressure is 7.2bar.

61
 b) SERVICE AIR COMPRESSOR:
The Service air compressor are used for cleaning,
and other purpose. Service air compressors are similar to instrument air compressor. The service
air compressors and instrument air compressors both are connected with common valve and when
instrument air compressors are stop working than common valve is automatic open during 5min
and service air compressor take the compressed air to the instrument air compressor.

TECHANICAL DATA OF AIR COMPRESSOR

i. Rore
L.P. Cylinder : 470 mm
H.P. Cylinder : 265 mm
ii. Stroke : 150 mm
iii. Compressor Speed : 625 rpm
iv. Free air delivery : 25.00 m3/min
v. Piston Displacement : 32.38 m3/min
vi. Suction Pressure : 0.965 kg/cm2
vii. Working Pressure : 8.80 kg/cm2
viii. Lub oil Pressure : 2 to 4 kg/cm2
ix. Total cooling water : 200 l.p.m.
x. Total weight of compressor : 4000 kg
xi. Overall dimension of compressor : Length: 3200 mm
Width: 2800 mm
Height: 2010 mm
xii. Electric motor : KEC SQ. MUHNL
CAGE SPDP
xiii. Power : 180 kw
xiv. Speed : 1500 (syn)
xv. Frame : LD3I5L
xvi. Belt Type : SPC 4500
FENNER MAKE
(QTY 7 NO’S)

62
 CONCLUSION

Working at G.H.T.P. Lehra Mohabbat was a very interesting and knowledgeable experience.
Working here, I learnt many things, I meet so many people who were talented in various fields.

Executive Engineer L.K.Bansal many ways, they helped me understand the working of the thermal
plant and I was involved in daily workings, which helped me gain a lot of confidence in my work.

In the end I would just like to say that it was very big opportunity for me to intern in G.H.T.P.
Lehra Mohabbat. I am thankful to all the people in G.H.T.P. Lehra Mohabbat with whom I have
worked for teaching me through their past experiences, helping improve my skills and having faith
in me.

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