A

Practical Training Report

On

Submitted in partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by:-
DESAI NIRAVKUMAR M.
(15012031009)
MECHANICAL ENGINEERING

GANPAT UNIVERSITY
DEPARTMENT OF MECHANICAL ENGINEERING
U. V. PATEL COLLEGE OF ENGINEERING
KHERVA, MEHSANA
 PREFACE
A student gets theoretical knowledge from classroom and
gets practical knowledge from industrial training. When these two aspects
of theoretical knowledge and practical experience together then a student
is fully equipped to secure his best.

In conducting the project study in an industry, students get

exposed and have knowledge of real situation in the work field and gains
experience from them. The object of the winter training cum project is to
provide an opportunity to experience the practical aspect of Technology in
any organization. It provides a chance to get the feel of the organization
and its function.

The fact that thermal energy is the major source of power

generation itself shows the importance of thermal power generation in
India – more than 60 percent of electric power is produced by steam plant
in India.

In steam power plants, the heat of combustion of fossil fuels

is utilized by the boilers to raise steam at high pressure and temperature.
The steam so produced is used in driving the steam turbine coupled to
generators and thus in generating ELECTRICAL ENERGY.
1. INTRODUCTION TO THE POWER PLANT:-

Now day electricity has become an essential part in everyone’s

routine life Our whole day starts and with it is the backbone of the
industrial and economical development of any country. Gandhinagar
thermal power station situated at the right bank of river sabarmati is
mainly constructed to meet with power need of North Gujarat and to
improve the voltage condition of the Western Grid.

Gandhinagar thermal power station unit 1 $ 2 are over 33 year

old. The place where electricity is produced is called power station. The
power station is classified according to fuel they use:

1. Diesel Power Station,

2. Thermal Power Station,
3. Hydro Power Station,
4. Nuclear Power Station,
5. Tidal Power Station,

Mostly the power station used in India is a thermal power station.

Hydro Power station needs the large amount of water at a desired
potential head. While Nuclear Power station has a limitation that it
requires a large amount of capital investment and power station of
nuclear waste is still a problem. This is not at solved.

So we have to depend upon the Thermal Power Plants, Which has the
major part in total Electricity generator of India. In India we have many
coal mines. Some of those places are Bihar Madhya Pradesh, etc. in India
some coal is exporting from Foreign like Australia, South Africa, etc. the
efficiency of the foreign coal is about 70 and that of India coal is about 35-
40.Steam coal is best coal in every respect. So availability of fuel is more
than other Hydro and Nuclear power plants.
 Station has taken shape in two phases : Stage-1 comprising of two
Units of 120 MW each for which the construction work had started in
year 1974 and completed within a record period of 3.5 year and that too
by saving of Rs.4/- crore budget provision of Rs.62.50/- crore. Since then
this two unit of 120 MW each is working continuously without any
major trouble.

Similarly Stage-2 consist of 3 Units of 210 MW each have also to

installed capacity of this T.P.S. Unit of 210 MW were installed in 1990-91
and running at full load generation without any problem. It also
enhances the capacity of T.P.S from 240 MW to 870 MW. The latest
Units-5 which started it’s generation of electricity in 1998.

Fig. India’s Installed Capacity (233930 MW)

2. A VIEW OF GANDHINAGAR T.P.S:-
3. Layout of T.P.S:-
4. PROCESS OF T.P.S:-

The transportation of coal from the coal-mine to the power plant

is done by Indian railway for oval handling the wagon carrying the coal is
fitted upside down by tippler mechanism and coal falls in the
underground hopper from the tippler hopper. The coal is supplied to
crusher house with the help of conveyers, in the crusher house the coal is
crushed and sized. The crushed coal coming out of the crusher us the
supplied to coal bunker with the help of a conveyor belt. Crushed coal is
feed to the pulverize through feeder. Hot air is passed through the feeder
to dry the coal before being feed to the pulverize. Coal is carried from the
bowl mill with the help of air force. This further causes coal through sort
combustion chamber.
The hot gases produced due to the combustion of coal Passover
the water super heater, Re-heater, Economizer, Air pre-heater, etc., then
rejected to the atmosphere through the chimney. An ID fan is produced
at the base of a chimney to suck the hot fuel. Chimney fuel gases also
pass through ESP that is type of dust collector.
The heat in the fuel gases us utilized while passing through the
system. It gives latent heat to the feed water passing through the water
tube and so the water gets evaporated. While it is passing over super
heater and re-heater the hot fire gas's superheat the wet steam which is
produced due to evaporation of water in drum and thus increase the
plant efficiency.
The feed water is pumped to water drum through the LP heater,
HP heater and then economizer with the help of the feed pump. In the
economizer water is preheated and it gets to sensible heal by using the
gases. The water gets evaporated in the drum and steam is produced,
which is wet steam. Wet steam is dried and superheated by super heater.
Then it is supplied to the turbine. First the steam is supplied to the HP
turbine, The high velocity steam rotates the rotor blade and thus turbine
shaft.
 The steam from the HP turbine is supplied to IP and then low
pressure steam is supplied to the LP turbine. In between these parts the
steam is reheated and also supplied LP & HP feed water heater. The
excess steam from turbine is condensed in condenser by circulation of
cooling water. Due to condensation of steam cooling water gets heated as
it extracts the heat from steam. The cooling water is further cooled down
in cooling water is further recycled in condenser with CW pump.

The DM water produced in condenser fins collected in the hot well at the
bottom of the condenser. The water from hot well passed through the LP
feed heater than the feed water is passing through detractor to remove
gasses from the water,which cause corrosion. Cooling tower may be
natural or artificial further cools down the cooling water in the cooling
tower the hot water is spayed from height and thus exposing the
removed to the atmosphere and the water become cool and collected in
the pond. This cooling tower is further recycled in condenser with CW
pump.
Then through BFP water is passed to economizer through HPH and
thus water recycled to the boiler drum, Then further the steam produced
and which rotates the turbine. The turbine rotates the alternator
connected to the same shaft and at the way corrosion from kinetic energy
of steam to mechanical energy and then finally to the electric energy is
done.
5. COAL YARD:-

 In the coal yard the wagon full of coal is emptied automatically.

 In this first the wagon is sprayed of water.
 Then the wagon is clamped by horizontal and vertical clamp.
 Then the dc motors rotates the bridge and the coal is emptied from
the wagon.
 The floor is at 40m depth.
 Then the bridge came into original position.
 The rack pulls out the wagon from the track.
 The rack is worked by motor.

Fig. Wagon Trippler

 6. COAL CRUSHER:-
 The coal crusher is used to crush the coal.
 From the floor the rack pull out the coal.
 In the crusher there is one mill which crack the large stone of coal.
 There is magnet used to pull out the metal particles present in the
coal.
 There is always 2 gates are used.
 One in working condition while another is in stand by.
 From the crusher the coal is stored in the bunker or either on the
ground.
 The continues water is sprayed on the coal.
 Due to property of the coal the coal burn in the air so the water
spray is required.
 The JCB is used to supply coal to bunker from ground storage.


7. BUNKER:-
 The bunker is the one type of storage.
 The belt is used to pull out the coal from crusher.
 The depth of the bunker is 12m.
 8m cylindrical and 4m conical shape.
 From the bunker the coal enters into the feeder.
 From the feeder the coal enter into the coal mill.
8. COAL MILL:-
 The coal needed to be fine particles to burn efficiently.
 The size of the coal particles are 200-400 mesh.
 The mesh is unit which is described as the parts per square inch.
 Here the bowl type coal mill used.
 The saucer type bed is rotating with the help of motor.
 From the feeder the centrally located pipe feed the coal into mill.
 The roller is used to crush the coal.
 While the coal crushed from the mill is of size of 200-400 mesh.
 The P.A. Fan blows the air from the bottom and fly out the crushed
coal into the boiler from the mill.
 The 4 pipe is used as outlet.
 The metal particles and another heavy particles are diffused away at
bottom.
 The excitation force is provided to the roller from behind.
 The nitrogen shock absorber tank is also used to absorb the shock
on the roller.
 The lubrication is required in the roller.
 The lubrication pump is existing there.
 The coal is prevented to enter into the bearing so seal pump is also
used.
 The speed of the coal crushed in the mill is managed by managing
the speed of the feeder.
 Coal is grounded to powdery form in bowl mill. This finely grounded
coal is known as pulverized coal. Bowl mill consists of a round
metallic table and three rollers. Rotating table is made to rotate with
the help of a motor. There are three large rollers which are at a
spacing of 120°.When there is no coal these rollers does not rotate
but when coal is fed to the table it packs between the table on the
forces the rollers to rotates.Coal is crushed by the crushing action
between table and rollers.
TECHNICAL DATA:-

 No. of coal mills: 6 Nos.

 Maximum capacity : 45 TPH
 Mill speed : 26.4 rpm
 No. of coal Bunkers : 6 Nos
 Mill type : Medium speed vertical grinder roller
 Coal fineness : 75 μ
 Capacity of coal feeder : 50 TPH
 Outlet PA / Coal temp. : 85° C

Fig. coal mill inside view

10. Oil Plant:-

 Oil is the auxiliary or supporting fuel to five initial heats to the boiler
before giving the supply of the coal to the boiler. There are two
type of oil used in GTPS.

1. LDO (light diesel oil)

2. RFO (residual fuel oil)

HOW LDO AND FO ARE SUPPLIED TO THE

BOILER?
L.D.O (LIGHT DIESEL OIL):-

It comes through tankers and store in the main LDO storage tank. Now,
by using centrifugal pump, it is taken from the tank and supplied in the
boiler.

R.F.O (RESIDUAL FUAL OIL):-

It comes through railway wagons. As FO is very thick so we have to

provide some amount of heat to convert the thick oil into liquid from of
oil for tripping action and the taken into the FO storage tank and it is
taken into boiler through the pump.

BURNIG OF LDO AND RFO:-

From the bottom side of the burning zone of boiler, LDO & RFO are
entered in to the boiler and fired to give heat to boiler
For firing of LDO. LDO + Air are entered and ignited through igniter. After
ignition of LDO, RFO + Steam and ignited through igniter. Igniter fan is
provided to give some air for heating purpose of LDO and RFO.
11. Boiler:-

 Boiler is the heart of the thermal power plant. The boiler ids
mounted properly and properly with suitable accessories produces
steam of the desired quality and quantity. The boiler in the
especially in GSECL is,
1. High pressure
2. High temperature
3. Tangentially fire type
4. Water tube type
5. Pulverized fuel type
6. Balanced draft type
7. Vertical and pendent type boiler

MAIN ACCESSORIES OF BOILER ARE AS UNDER:-

1. Boiler drum,
2. Super heater,
3. Reheater,
4. Economizer,
5. Primary air heater,
6. Secondary air heater,

11.1 BOILER DRUM:-

 The boiler drum is made of heavy duty steel plate. The inlet water to
boiler drum is coming from economizer which has increase up to the
temperature 250`C. Fore down comers are attached to a single ring
header, which is at bottom of the furnace. This ring header is
extended upwards as.
 These tubes are attached with the wall of the furnace and finnaly
they reach to the boiler drum. The water the boiler drum is through
down comers towards the ring headers. Then their water goes into
water where it is converted in to steam. So, both water and steam
are present inside the water tube walls.
11.2 SUPER HEATER:-
 The steam separated from water in boiler drum never dry. This
causes the corrosion of blades. For reason the steam should the
steam should be dry it is provided by super heating inside the super
heater.
 These rises the temperature steam up to 540`C super heated steam
are placed in the path of the flue gases. Here, super heater are
found inside the boiler drum namely;
1. Low temperature super heater
2. De-super heater
3. Platen super heater
4. Final or Pendent super heater

 First of all, the steam from the boiler drum enters into the low
temperature super heater. Then steam passes to plane super
heater through desuperheater and finnaly it reaches to final super
heater where it temperature is taken up to 540`C and the pressure
of 135 kg/cm2, It is given to the high pressure turbine.

Fig. Super heater

Fig. Inside View of super heater in Boiler
11.3 REHEATER:-
 They are similar to super heater modern utility boiler for boosting
plate efficiency. Reaheater obtain the used steam from the pressure
turbine at a pressure lower than the boiler pressure and which is
nearly 34.1 kg/cm2.

 The low pressure steam passing through reheater is heated to 540◦

and then it is introduced in the I.P turbine. The steam entering the
I.P turbine has pressure of 32.1 kg/cm2.

Fig. Reheater
11.4 ECONOMIZER:-
 The purpose of economizer is to preheat the boiler feed water
before it is introduced in the boiler drum and there by recover
some of the from the flue gases leaving the boiler.
 Each section of the economizer is composed of a number of
parallel tube circuits. All the tube circuit originates from the inlet
header and discharge in to the outlet header through the
economizer immediate headers.
 The external surface of the tubes is kept dirt free since it is a bad
conductor of heat. This is necessary to increase the efficiency of the
economizer inlet header via the boiler feed discharge.
 The feed water is in such a way that counter direction (upward)
than that of flue gases. thereby most efficiency heat transfer is
accomplished from the outlet via the economizer outlet lines the
feed water is let to drum .the outlet temperature of water coming
from economizer is nearly 250°C.

Fig. Economizer
11.5 PRIMARY AIR HEATER:-
 In order to have an efficient combustion in the boiler the coal
should be somewhat before it is fired. To achieve this purpose the
primary air, this is heated in primary air heater.

 The primary air heater is placed in the path of flue gases, and is
heated in between economizer and secondary air heater in the
boiler. This is order to reclaim the heat from the outgoing flue
gases. This is partially recovered in economizer. Primary air fans
provided the primary air here.

11.6 SECONDARY AIR HEATER:-

 The secondary air heater, which is used combustion purpose

should be not enough for and efficient combustion in the furnace if
the boiler. The secondary air heater servers this purpose.

 It is also installed in the path of flue gases in order to reclaim the

remaining heat from the flue gases. This is the last heat recovery
unit. The hot flue gases leaving secondary air heater pass a
temperature of 150°C.
12. CONSTRACTION AND WORKING OF BOILER:-

 Boiler is handling type, tangentially fired. It is constructed by using

number of tubes in which steam is generated due to firing of coal.
Boiler is hanging from the toper side through some rigid and flexible
supports.

 At the bottom portion of boiler, seal drum is given in which water is

feed which is used to prevent entering of air and other substances
in boiler. At the outer periphery of boiler, water wall tubes are
provided which is used for cooling purpose o boiler heat absorption.

 In boiler, 5 cm of water pressure is created as having the cause of

flue gas cannot come outside so such type of vacuum is provided.

 Now, boiler is ignited in different tubers. Each boiler has 6 coal mills
and 6 tubers. LDO and FO are supplied in between two tubers. And
coal is feed into the boiler from four corners of the boiler through
nozzles which is in pulverized from and it will constitute tangentially
firing zone. It is burnt by giving initial heating by LDO &FO.

 Now water enters into the boiler tubes through BFP. Due to the flue
gas water is heated and collected in the boiler drum. Here through
turbo- separator, steam is separated from the water and taken to
the HP turbine to rotate the rotor and the power generation.

 After burning of fuel, flue gases are produced and pass through the
super heater and reheated, economizer, air preheater, ESP and
finally to the suction of ID fan and exhausted in atmosphere
through chimney.
Fig. Boiler inside View
13. DRAUGHT SYSTEM:-
Large amount of air is required for combustion of fuel. The gaseous
combustion products in huge quantity have also to be removed
continuously from the furnace. To produce the required flow of air or
combustion gas, a pressure differential is needed. The term “draught” or
“draft” is used to define the static pressure in the furnace, in the various
ducts, and the stack.
The function of the draught system is basically two folds:
• To supply to the furnace the required quantity of air for complete
of fuel.
• To remove the gaseous products of combustion from the furnace
and throw these through chimney or stack to the atmosphere.
• There are two ways of producing draught:
• Natural draught
• Mechanical draught

Natural Draught:- The natural draught is produced by a chimney or a

stack. It is caused by the density difference between the atmospheric air
and the hot gas in the stack.

Mechanical Draught:- Mechanical draught is produced by fans.

Induced and Forced Draught Fans:-

• Big fans may be used for sucking and throwing out the flue gas
through the chimney, thereby creating adequate draught inside the
furnace.
• Such Fans are termed as Induced Draught Fans. Forced draught
Fans may also be deployed for supply of required quantity of
combustion air and maintaining a positive draught inside the
furnace.
• The flue gas will be pushed out the stack with the draught
pressure available in the furnace.
13.1 FORCED DRAUGHT FAN:-

• Air drawn from atmosphere is forced into the furnace, at a pressure

higher than the outside atmosphere, by big centrifugal fan or fans to
create turbulence and to provide adequate Oxygen for combustion.
• Hence the system is known by the name Forced draught system and
the fan, used to push through combustion air under pressure, is called
Forced Draught Fan. F D fan is normally located at the front or
sideways of the furnace.

Fig. FD Fan
13.2 INDUCED DRAUGHT FAN:-

• Instead of drawing atmospheric air and pushing through furnace, a

centrifugal fan can be deployed to draw out the air from the furnace
and throw out through the chimney, thereby creating negative
pressure in the combustion zone and maintain the negative draught
through out the furnace.
• The system is called Induced Draught system and the fan deployed
for this purpose is known as Induced Draught Fan.
• In the Induced Draught system, the fan is fitted at back end of the
furnace or near the base of the chimney.
• Due to the negative pressure created inside the furnace, by the
action of the fan, flue gas will not come out of combustion space
i.e. Furnace.
• The entry of air to Boiler is regulated through air registers and
dampers.
• For similar capacity boilers, the size of an induced draught fan will be
more than the size of the forced draught fan required for a forced
draught system.
• This is because the products of combustion is always much higher in
volume than the volume of combustion air handled by the forced
draught fan.
• Further the flue gas is hotter and the density is less. Hence the
volume is much more.
• According to Charles Law, when a gas is heated the volume will
proportionately increase at constant pressure, with the raise in
temperature.
• According to Boyles Law, if pressure inside a vessel is increased, the
volume will proportionately decrease and the vice-versa is also true
(P ∝ 1/V).
Fig. ID Fan
14. PRIMARY AIR FAN:-

• These are the large high pressure fans which supply the air needed
to dry and transport coal either directly from the coal mills to the
furnace or to the intermediate bunker.
• These fans may be located before or after the milling equipment.
The most common applications are cold primary air fans, hot
primary air fans.
• The coal primary air fan is located before air heater and draws air
from the atm. And supplies the energy required to force air through
air heaters, ducts, mills and fuel piping.
• With a cold air system like this the FD fan may be made smaller as PA
fan supply part of combustion air.
• For primary air fans boosts the air pressure from air heaters for
drying and transporting coal from pulverisers in these systems the
total air has to be handled by FD fans and each mill will be provided
with a primary air fan at the mill inlet side the primary fan in these
case has to handle hot air probably with some amount of fly ash
carried from the air pre-heater.

15. AIR PREHEATER:-

• Air preheater are in generally divided into following two types:

Recuperative

Regenerative
• In Recuperative APH, heat is directly transferred from the hot
gases to the air across the heat exchanging surface.
• They are commonly tubular, although some plate types are still in
use. Tubular units are essentially counter-flow shell-and-tube heat
exchangers in which the hot gases flow inside the vertical straight
tubes and air flows outside.
• Baffles are provided to maximize air contact with the hot tubes.
• Regenerative APH are also known as storage type heat exchangers,
have an energy storage medium, called the matrix, which is
alternately exposed to the hot and cold fluids. When the hot flue
gases flow through the matrix in the first half of the cycle, the matrix
is heated and the gas is cooled. In the next half of the cycle when air
flows through the matrix, air gets heated and the matrix is cooled. The
cycle repeats itself.

Fig. Air Preheater

16. 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
deaerator boiler feed water storage tank.

Fig. Deaerator
17. STEAM TURBINE:-

17.1 INTRODUCTION:-

• Turbine is a machine in which a shaft is rotated steadily by impact or

reaction of current or stream of working substance (steam, air,
water, gases etc) upon blades of a wheel.
• It converts the potential or kinetic energy of the working substance
into mechanical power by virtue of dynamic action of working
substance. When the working substance is steam it is called the
steam turbine.

Fig. Inside View of Turbine

17.2 PRINCIPAL OF OPERATION OF STEAM TURBINE:-

• Working of the steam turbine depends wholly upon the dynamic

action of Steam. The steam is caused to fall in pressure in a passage
of nozzle: doe to this fall in pressure a certain amount of heat
energy is converted into mechanical kinetic energy and the steam is
set moving with a greater velocity.
• The rapidly moving particles of steam, enter the moving part of the
turbine and here suffer a change in direction of motion which gives
rose to change of momentum and therefore to a force.
• This constitutes the driving force of the machine. The processor of
expansion and direction changing may occur once or a number of
times in succession and may be carried out with difference of detail.
• The passage of steam through moving part of the commonly called
the blade, may take place in such a manner that the pressure at the
outlet side of the blade is equal to that at the inlet inside.Such a
turbine is broadly termed as impulse turbine.
• On the other hand the pressure of the steam at outlet from the
moving blade may be less than that at the inlet side of the blades; the
drop in pressure suffered by the steam during its flow through the
moving causes a further generation of kinetic energy within the
blades and adds to the propelling force which is applied to the turbine
rotor. Such a turbine is broadly termed as impulse reaction turbine.
• The majority of the steam turbine have, therefore two important
elements, or Sets of such elements.
• These are the nozzle in which the system expands from high
pressure end a state of comparative rest to a lower pressure end a
status of comparatively rapid motion.
• The blade or deflector, in which the steam particles changes its
directions and hence its momentum changes .
• The blades are attach to the rotating elements are attached to the
stationary part of the turbine which is usually termed the stator,
casing or cylinder.
 Although the fundamental principles on which all steam turbine
operate the same, yet the methods where by these principles carried
into effect very end as a result, certain types of turbine have come
into_existence.
Fig. Turbine Stage
18. DESCRIPTION OF STEAM TURBINES:-

18.1 HP TURBINE:-

• The HP casing is a barrel type casing without axial joint. Because of

its rotation symmetry the barrel type casing remain constant in
shape and leak proof during quick change in temperature.
• The inner casing too is cylinder in shape as horizontal joint flange are
relieved by higher pressure arising outside and this can kept small.
Due to this reason barrel type casing are especially suitable for quick
start up and loading.
• The HP turbine consists of 25 reaction stages. The moving and
stationary blades are inserted into appropriately shapes into inner
casing and the shaft to reduce leakage losses at blade tips.

Fig. HP Turbine
18.2 IP TURBINE:-

• The IP part of turbine is of double flow construction. The casing of IP

turbine is split horizontally and is of double shell construction.
 The double flow inner casing is supported kinematically in the
outer casing.
• The steam from HP turbine after reheating enters the inner casing
from above and below through two inlet nozzles.
• The centre flows compensates the axial thrust and prevent steam
inlet temperature affecting brackets, bearing etc.
• The arrangements of inner casing confines high steam inlet condition
to admission branch of casing, while the joints of outer casing is
subjected only to lower pressure and temperature at the exhaust of
inner casing.
• The pressure in outer casing relieves the joint of inner casing so
that this joint is to be sealed only against resulting differential
pressure.
• The IP turbine consists of 20 reaction stages per flow. The moving and
stationary blades are inserted in appropriately shaped grooves in
shaft and inner casing.

Fig. IP Turbine
18.3 LP TURBINE:-

• The casing of double flow type LP turbine is of three shell design.

The shells are axially split and have rigidly welded construction.
• The outer casing consist of the front and rear walls , the lateral
longitudinal support bearing and upper part.
• The outer casing is supported by the ends of longitudinal beams on
the base plates of foundation.
• The double flow inner casing consist of outer shell and inner shell.
The inner shell is attached to outer shell with provision of free
thermal movement.
• Steam admitted to LP turbine from IP turbine flows into the inner
casing from both sides through steam inlet nozzles.

Fig. LP Turbine
18.4 TURBINE DATA:-

TYPE:-
Horizontal, tandem, compounded, reheate impulse turbine, stop
valve steam condition 126.55kg/cm2 and 538°C.

SPEED:-
-3000rpm, No of extraction is 6

NO OF STAGE:-
- HP cylinder 11
- IP cylinder 13
- LP cylinder 6, double flow

18.5 LOSSES IN STEAM TURBINE:-

• Friction losses
• Leakage losses
• Wind age loss( More in Rotors having Discs)
• Exit Velocity loss
• Incidence and Exit loss
• Secondary loss
• Loss due to wetness
• Loss at the Bearings (appx 0.3% of total output)
• Off design losses
18.6 MAIN LOSSES IN TURBINE:-

FRICTION LOSS:-
• It is more in Impulse turbines than Reaction Turbines,because
impulse turbines uses high velocity of steam and further the flow
in the moving blades of the Reaction turbines is accelerating
which leads to better and smooth flow(Turbulent flow gets
converted to Laminar flow).

LEAKAGES LOSS:-
 It is more in Reaction turbines than Impulse turbines because there
is Pressure difference across the moving stage of reaction turbines
which leads to the Leakages. In Impulse turbine such condition is not
there.
• Leakage loss predominates over friction losses in the High
Pressure end of the Turbine
• Friction Losses predominates over the Leakage's Loss in the Low
Pressure end of the Turbine.
• It is observed that the Efficiency of The IP Turbine is the
maximum followed by The HP and LP Turbine.

18.7 LUBICATION OF TURBINE:-

 After knowing about the steam rotates the turbine with very high
speed as 3000rpm, so in bearings some lubrication oil is used from
main tank through three different pumps.
1. MOP ( Main Oil Pump )
2. AOP ( auxiliary Pump )
3. JOP ( Jet Oil Pump )
 MOP and AOP are used for the distribution of oil fro lubricating
purpose of the speed 3000rpm and less then 3000rpm respectively.
 JOP is used to lift the rotor by providing the pressure of jet oil pump.
19. GENERATOR:-
• An alternator is an electromechanical device that converts
mechanical energy to alternating current electrical energy.
• In principle, any AC generator can be called an alternator, but
usually the word refers to small rotating machines driven by
automotive and other internal combustion engines.
• Generator is connected with the all HP, IP and LP turbines so when
the turbines rotates by the pressure of the steam the generator also
rotate and due to magnetic field it generates electricity.
• In 330MW unit the generator is connected with one HP turbine, one
IP turbine and one LP turbine but In 660MW unit the generator is
connected with one HP turbine, one IP turbine and two LP turbine.

Fig. Generator
20. ASH HANDLING & DUST COLLECTION:-

ELECTROSTATIC PRECIPITATOR(ESP):-

• It is a device which removes dust or other finely divided particles

from flue gases by charging the particles inductively with an electric
field, then attracting them to highly charged collector plates. Also
known as precipitator.
• The process depends on two steps. In the first step the suspension
passes through an electric discharge (corona discharge) area where
ionization of the gas occurs. The ions produced collide with the
suspended particles and confer on them an electric charge.
• The charged particles drift toward an electrode of opposite sign and
are deposited on the electrode where their electric charge is
neutralized. The phenomenon would be more correctly designated
as electrode position from the gas phase.

Fig. ESP
Fig. Inside view of ESP
21. CONDENSER:-

• Steam after rotating steam turbine comes to condenser. Condenser

refers here to the shell and tube heat exchanger (or surface
condenser) installed at the outlet of every steam turbine in Thermal
power stations of utility companies generally. These condensers are
heat exchangers which convert steam from its gaseous to its liquid
state, also known as phase transition.
• In so doing, the latent heat of steam is given out inside the
condenser. Where water is in short supply an air cooled condenser is
often used.
• An air cooled condenser is however significantly more expensive
and cannot achieve as low a steam turbine backpressure (and
therefore less efficient) as a surface condenser.
• The purpose is to condense the outlet (or exhaust) steam from
steam turbine to obtain maximum efficiency and also to get the
condensed steam in the form of pure water, otherwise known as
condensate, back to steam generator or (boiler) as boiler feed
water.

Fig. Condenser
22. COOLING TOWERS:-

• 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 recalculated through the
system, affording economical operation of the process

COOLING TOWER
• Inlet water temperature : 60 °C
• Outlet water temperature : 35 °C

Fig. Cooling Tower

23. SMOKE STACK/CHIMNEY:-

• A chimney is a system for venting hot flue gases or smoke from a

boiler, stove, furnace or fireplace to the outside atmosphere.
• They are typically almost vertical to ensure that the hot gases flow
smoothly, drawing air into the combustion through the chimney
effect (also known as the stack effect).
• The space inside a chimney is called a flue. Chimneys may be
found in buildings, steam locomotives and ships.
• In the US, the term smokestack (colloquially, stack) is also used
when referring to locomotive chimneys.
• The term funnel is generally used for ship chimneys and sometimes
used to refer to locomotive chimneys. Chimneys are tall to increase
their draw of air for combustion and to disperse pollutants in the flue
gases over a greater area so as to reduce the pollutant concentrations
in compliance with regulatory or other limits.
• These are 220M tall RCC structures with single / multiple flues
inside the concrete shells. The height of these chimneys varies
depending on the location of power plant.

Fig. Chimney
24. SALIENT FEATURES OF 210 MW UNIT OF GTPS:-

PLANT CAPACITY : 3*210MW

BOILER CAPACITY : 690 tones/hour of steam at
Pressure of 136 kg/(cm)squ and 540`C
COAL HANDLING : 1000 tones/hour
CHIMNEY HEIGHT : 120 m for 3 & 4 and 220 m for unit 5
COOLING TOWER HEIGHT : 121 m for 3 & 4 and 131 m for unit 5
COOLING TOWER CAPACITY : 33000 3m / hr
COOLING WATER PUMP : 16,500 3m/hour no:3
CAPACITY
CAPACITY OF CONDENSOR : 700 t/hour
CAPACITY OF SERVICE : 150 3m
WATER OVER HEAD TANK
CAPACITY OF CLARIFIER : 2700 3m
TANK
CAPACITY OF STEP UP : 140 MVA
TRANASFORMER
STEP UP RATIO : 15.7 kv / 220 kv
CAPACITY OF UNIT : 15 MVA
AUXILARY
STEP DOWN RATIO : 13.8 kv / 6.6 kv
CAPACITY OF FO STORAGE : 2*15680 3m
TANK
CAPACITY OF LDO STORAGE : 400 tones
TANK
CAPACITY OF : 160 T / hr
ASH HANDALING
24. CONCLUSION:-
• The first phase of practical training has proved to be quiet fruitful. It
provided an opportunity for encounter with such hardworking
engineers.
• The architecture of the power plant the way various units are linked
and the way working of whole plant is controlled make the student
realize that engineering is not just learning the structured description
and working of various machines, but the greater part is of planning
proper management.
• It also provides an opportunities to learn low technology used at
proper place and time can cave a lot of labour But there are few
factors that require special attention. Training is not carried out
into its tree sprit.
• It is recommended that there should be some project specially
meant for students where presence of authorities should be
ensured. There should be strict monitoring of the performance of
students and system of grading be improved on the basis of work
done.
• However training has proved to be quite fruitful. It has allowed an
opportunity to get an exposure of the practical implementation to
theoretical fundamentals.