TRAINING REPORT

AT
G.H.T.P BATHINDA

Submitted To - Submitted By –
Dr. Ved Parkash Lakhichan Roy
B.Tech (EE)
15110293
 ACKNOWLEDGEMENT

I am extremely thankful & indebted to the numerous PSPCL Engineers,

who provided vital information about the functioning of their department
thus helping me to gain an overall idea about the working of organization. I
am highly thankful for the support & guidance of each of them.
I am highly indebted to my project guide, Er. Baljeet Singh for giving
me his valuable time and helping me to grasp the various concepts of
switchyard equipments.
Last but not the least, I would like to thank my parents & all my fellow
trainees who have been a constant source of encouragement & inspiration
during my studies & have always provided me support in every walk of life.

-Lakhichan Roy

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 ABOUT PSPCL

Punjab State Power Corporation Limited (PSPCL) is the electricity generating company of the
Government of Punjab state in India. PSPCL was incorporated as company on 16-04-2010 and
was given the responsibility of operating and maintenance of State's own generating projects.
The business of Generation of power of erstwhile PSEB was transferred to PSPCL. The existing
Thermal Power Plants under PSPCL are GURU NANAK DEV THERMAL PLANT
BHATINDA, GURU GOBIND SINGH SUPER THERMAL PLANT ROPAR and GURU
HARGOBIND THERMAL POWER PLANT LEHRA MOHABBAT (BHATINDA). The
existing Hydro Power Plants are RANJIT SAGAR DAM (HYDRO ELECTRIC PROJECT),
SHANAN POWER HOUSE (HYDRO ELECTRIC PROJECT), ANANDPUR SAHIB HYDEL
PROJECT (HEP), MUKERIAN HYDEL PROJECT STAGE - I and U.B.D.C. HYDRO
ELECTRIC POWER HOUSE STAGE I & II.

“MEGAWATT STORY”

Total power from state's current sources 6,950 MW

Peak demand in 2011-12 10,010 MW
Demand increase per year 8%
Present shortfall 3,100 MW
Thermal generation (Ropar, Lehra Mohabbat, Bathinda) 2,620 MW
Hydel generation 1,000 MW
BBMB projects 1,250 MW
Central pool and banking 3,200 MW
Solar (9 plants) 14.5 MW
Biomass (3 plants) 6 MW
Micro Hydel (2 plants) 0.85 MW

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 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 phases, 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

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 Brief History of Plant
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 Distt. Bathinda. The others favorable factors were low initial cost and
generation period as compared to hydroelectric generating stations, its good railway
service and proximity to load center.
Initially it was going to set up at Bathinda under GNDTP but the air force
personal restricted its set up at Bathinda hence plant shifted to Lehra Mohabbat
about 22 Km from Bhatinda city. Later this plant was approved as a separate
autonomous body with its name as Guru Hargobind Thermal Plant. The
Construction of plant commenced in 1992.
It consists of 2 stages: -
Stage 1: -
First unit commissioned on 27/12/1997
Second unit commissioned on 16/10/1998
Stage 2: -
Third unit commissioned on 16/10/2008
Fourth unit commissioned on 31/01/2009
The capacity of both units of stage 1 is 210 MW each and that of stage 2 is 250 MW
each. It meets 20-25% of total power requirement of Punjab. The main companies
whose technology paved the way for the plant are Tata Honeywell and BHEL in
turbine and boiler control.

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 Layout Of Plant

THERMAL PLANT PRACTICAL OVERVIEW

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 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 equipment’s 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 encloses 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
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.

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 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.

 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 is
designed as a way that it will lift the wagon in easy way. In this mechanism, 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 mechanism. It lifts the table and unloads the wagon. The coal
goes on the Apron delt trough the hopper.

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 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.
 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

TECHANICAL DATA
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 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

2 Ring granulator (secondary crusher): 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 purposes. There is built
in arrangements of bypassing the crusher by which the coal can be fed directly to the
conveyors bypassing crush.

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

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 STACKING / RECLAIMING: 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.

 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.

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 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, pulverize 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.

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 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 driven motor connected with dyna drive 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.

 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.

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 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 Pulverizes:
BOWL MILL : XRP-803,
Coal pulverizing capacity : 36.9 Ton/hr,
Motor : 340KW, 6.6KV

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 emptying 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.

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Coal Pulverizing System (Bowl Mill)

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 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 lubricating is done. It is done
in the self-rotating roller and under the bowl plate, bearings are also provided here to eliminate
the hindrance.

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 COAL TRANSFER SYSTEM TO BOILER

 PARTS OF COAL TRASPOTATION TO THE BOILER:

 COAL BUNKER
 COAL FEEDER
 BOWL MILL
 TRANSFER PIPE
 FURNANCE

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 Brief description of all outdoor Equipment’s:

 Bus Bars: Bus bar is a term used for main bar of conductor carrying an electric current
to which many connections can be made. These are mainly convenient means of
connecting switches and other equipment’s into various arrangements. At GHTP there are
two 220 KV bus bars and two 66 KV bus bars which are made of aluminum. All
incoming and outgoing supplies are connected through the bus bars.
Specifications:
Minimum short circuit current in bus bars 40 KV
Minimum phase to phase clearance 2.5 M
Number of horizontal levels of tubular bus bar/flexible bus bars 2.0 M
Height of tubular bus-bar of first level above ground 6 m
Height of tubular bus-bar of second level above ground 4 m
Tubular aluminum bus bar AL ASTMB241 4"IPS (International pipe standard)
Lighting Arrestors: These are equipment’s designed to protect insulators of power
lines and electrical installations from lightning surges by diverting the surge to earth.
High Voltage Power System experiences over voltages that arise
due to natural lightning or the inevitable switching operations.
Under these overvoltage conditions, the insulation of the power
system equipment’s is subjected to electrical stress which may lead
to catastrophic failure. Broadly, three types of overvoltage occur in
power systems: (i) temporary over-voltages, (ii) switching over
voltages and (iii) lightning overvoltage. The duration of these over
voltages varies in the ranges of microseconds to sec depending
upon the type and nature of overvoltage. Hence, the power system
calls for overvoltage protective devices to ensure the reliability.
Conventionally, the overvoltage protection is obtained by the use
of lightning / surge arresters. Under normal operating voltages, the
impedance of lightning arrester, placed in parallel to the equipment to be protected, is very high
and allow the equipment to perform its respective function. Whenever the overvoltage appears
across the terminals, the impedance of the arrester collapses in such a way that the power
system equipment would not experience the overvoltage. As soon as the overvoltage disappears,
the arrester recovers its impedance back. Thus, the arrester protects the equipment from
overvoltage.
The technology of lightning arresters has undergone major transitions during this century. In the
early part of the century, spark gaps were used to suppress this overvoltage. The silicon carbide
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gapped arresters replaced the spark gaps in 1930 and reigned supreme till 1970. During the mid-
1970s, zinc oxide (ZnO) gapless arresters, possessing superior protection characteristics,
replaced the silicon carbide gapped arresters. Usage of ZnO arresters have increased the
reliability of power systems many fold.
 Current Transformer
In electrical engineering, a current transformer (CT) is used for measurement of electric
currents. Current transformers, together with voltage transformers (VT) (potential transformers
(PT)), are known as instrument transformers. When
current in a circuit is too high to directly apply to
measuring instruments, a current transformer produces
a reduced current accurately proportional to the
current in the circuit, which can be conveniently
connected to measuring and recording instruments. A
current transformer also isolates the measuring
instruments from what may be very high voltage in
the monitored circuit. Current transformers are
commonly used in metering and protective relays in
the electrical power industry.
Current transformers are used extensively for
measuring current and monitoring the operation of the power grid. Along with voltage leads,
revenue-grade CTs drive the electrical utility's watt-hour meter on virtually every building with
three-phase service and single-phase services greater than 200 amps.
The CT is typically described by its current ratio from primary to secondary. Often, multiple
CTs are installed as a "stack" for various uses. For example, protection devices and revenue
metering may use separate CTs to provide isolation between metering and protection circuits,
and allows current transformers with different characteristics (accuracy, overload performance)
to be used for the devices.
Care must be taken that the secondary of a current transformer is not disconnected from its load
while current is flowing in the primary, as the transformer secondary will attempt to continue
driving current across the effectively infinite impedance. This will produce a high voltage
across the open secondary (into the range of several kilovolts in some cases), which may cause
arcing. The high voltage produced will compromise operator and equipment safety and
permanently affect the accuracy of the transformer.

 Potential Transformer:
These are used to step do the voltage to a level that the potential coils of indicating and
monitoring instruments can read. These are also used to feed the potential coils of relays. The

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primary winding is connected to the voltage being measured and the secondary winding to a
voltmeter. The PT steps down the voltage to the level of the voltmeter.

 Power Transformer
These are used to step up down the voltage from one ac voltage to another ac voltage level at
the same frequency. In GHTP there are 2 power transformers located in substation which
converts 220 KV to 66 KV of power 100 MVA each.

Losses in the transformer are of the order of 1% of its full load kW rating. These losses get
converted in the heat thereby the temperature of the windings, core, oil and the tank rises. The
heat is dissipated from the transformer tank and the radiator in to the atmosphere. Transformer
cooling helps in maintaining the temperature rise of various parts within permissible limits. In
case of Transformer, Cooling is provided by the circulation of the oil. Transformer Oil acts as
both insulating material and also cooling medium in the transformer. For small rating
transformers heat is removed from the transformer by natural thermal convection. For large
rating transformers, this type of cooling is not sufficient, for such applications forced cooling is
used.
As size and rating of the transformer increases, the losses increase at a faster rate. So oil is
circulated in the transformer by means of oil pumps. Within the tank the oil is made to flow
through the space between the coils of the windings.

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Several different combinations of natural, forced, air, oil transformer cooling methods are
available. The choice of picking the right type of transformer cooling method for particular
application depends on the factors such as rating, size, and location.

 Wave Trap
Line trap also is known as Wave trap. What it does is
trapping the high frequency communication signals sent on
the line from the remote substation and diverting them to
the telecom/teleportation panel in the substation control
room.
This is relevant in Power Line Carrier Communication
(PLCC) systems for communication among various
substations without dependence on the telecom company
network. The signals are primarily teleportation signals and
in addition, voice and data communication signals.
The Line trap offers high impedance to the high frequency
communication signals thus obstructs the flow of these signals in to the substation bus bars. If
there were not to be there, then signal loss is more and communication will be
ineffective/probably impossible.
 Indicating and Metering Instruments
Ammeters, voltmeters, wattmeter’s, KWHR meters and KVAR meters are installed in
substation to work over the currents flowing in the circuits and the voltages and power loads.
 Circuit breaker
Circuit breakers are mechanical devices designed to close and open
contact or electrical circuit under normal or abnormal conditions.
CB is equipped with a strip coil directly attached to relay or other
means to operate in abnormal conditions such as over power etc
In GHTP 3 types of circuit breakers are used. SF6 C.B.is used to
control 220 KV in switchyard. Vacuum C.B. is used to control 6.6
KV in switchgear and Air blast C.B. are used to control 415 V in
switchgear.
A circuit breaker is an automatically-operated electrical switch
designed to protect an electrical circuit from damage caused by
overload or short circuit. Its basic function is to detect a fault
condition and, by interrupting continuity, to immediately
discontinue electrical flow. Unlike a fuse, which operates once and

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then has to be replaced, a circuit breaker can be reset (either manually or automatically) to
resume normal operation. Circuit breakers are made in varying sizes, from small devices that
protect an individual household appliance up to large switchgear designed to protect high
voltage circuits feeding an entire city. Once a fault is detected, contacts within the circuit
breaker must open to interrupt the circuit; some mechanically-stored energy (using something
such as springs or compressed air) contained within the breaker is used to separate the contacts,
although some of the energy required may be obtained from the fault current itself. Small circuit
breakers may be manually operated; larger units have solenoids to trip the mechanism, and
electric motors to restore energy to the springs.The circuit breaker contacts must carry the load
current without excessive heating, and must also withstand the heat of the arc produced when
interrupting the circuit. Contacts are made of copper or copper alloys, silver alloys, and other
materials. When a current is interrupted, an arc is generated. This arc must be contained, cooled,
and extinguished in a controlled way, so that the gap between the contacts can again withstand
the voltage in the circuit. Different circuit breakers use vacuum, air, insulating gas or oil as the
medium in which the arc forms. Different techniques are used to extinguish the arc including:
 Lengthening of the arc
 Intensive cooling (in jet chambers)
 Division into partial arcs
 Zero point quenching (Contacts open at the zero current time crossing of the AC
waveform, effectively breaking no load current at the time of opening. The zero
crossing occurs at twice the line frequency i.e. 100 times per second for 50Hz ac and
120 times per second for 60Hz ac )
 Connecting capacitors in parallel with contacts in DC circuits
Finally, once the fault condition has been cleared, the contacts must again be closed to restore
power to the interrupted circuit.

 Capacitor Voltage transformer (CVT)

In high and extra high voltage transmission systems, capacitor
voltage transformers (CVTs) are used to provide potential outputs to
metering instruments and protective relays. In addition, when
equipped with carrier accessories, CVTs can be used for power line
carrier (PLC) coupling.A capacitor voltage transformer (CVT) is a
transformer used in power systems to step-down extra high voltage
signals and provide low voltage signals either for measurement or to
operate a protective relay. In its most basic form the device consists
of three parts: two capacitors across which the voltage signal is split,
an inductive element used to tune the device to the supply frequency
and a transformer used to isolate and further step-down the voltage
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for the instrumentation or protective relay. The device has at least four terminals, a high-voltage
terminal for connection to the high voltage signal, a ground terminal and at least one set of
secondary terminals for connection to the instrumentation or protective relay. CVTs are
typically single-phase devices used for measuring voltages in excess of one hundred kilovolts
where the use of voltage transformers would be uneconomical. In practice the first capacitor,
C1, is often replaced by a stack of capacitors connected in series. This results in a large voltage
drop across the stack of capacitors that replaced the first capacitor and a comparatively small
voltage drop across the second capacitor C2 and hence the secondary terminals.

 Isolator

In electrical engineering, a disconnecter or isolator switch is used to make sure that an

electrical circuit can be completely de-energized for service or maintenance. Such
switches are often found in electrical distribution and industrial applications where
machinery must have its source of driving power removed for adjustment or repair. High-
voltage isolation switches are used in electrical substations to allow isolation of apparatus
such as circuit breakers and transformers, and transmission lines, for maintenance.
In the substation following type isolators are used for the protection:
Horizontal break center rotating double break isolator:
This type of construction has three insulator
stacks per pole. The two one each side is
fixed and one at the center is rotating type.
The central insulator stack can swing about
its vertical axis through 900 . The fixed
contacts are provided on the top of each of
the insulator stacks on the side. The contact
bar is fixed horizontally on the central
insulator stack. In closed position, the
contact shaft connects the two fixed contacts.
While opening, the central stack rotates
through 900 and the contact shaft swings
horizontally giving a double break.
The isolators are mounted on a galvanized rolled steel frame. The three poles are interlocked by
means of steel shaft. A common operating mechanism is provided for all the three poles. One
pole of a triple pole isolator is closed position.

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  Pantograph isolator:

Illustrates the construction of a typical

pantograph isolator. While closing, the
linkages of pantograph are brought nearer by
rotating the insulator column. In closed
position, the upper two arms of the
pantograph close on the overhead station bus
bar giving a grip. The current is carried by
the upper bus bar to the lower bus bar
through the conducting arms of the
pantograph. While opening, the rotating
insulator column is rotated about its axis.
Thereby the pantograph blades collapse in
vertical plane and vertical isolation is obtained between the line terminal and pantograph upper
terminal.
Pantograph isolators cover less floor area. Each pole can be located at a suitable point and the
three poles need not be in one line, can be located in a line at desired angle with the bus axis .
 Isolator with earth switches (ES):
The instrument current transformer (CT) steps down the current of a circuit to a lower value and
is used in the same types of equipment as a potential transformer. This is done by constructing
the secondary coil consisting of many turns of wire, around the primary coil, which contains
only a few turns of wire. In this manner, measurements of high values of current can be
obtained. A current transformer should always be short-circuited when not connected to an
external load. Because the magnetic circuit of a current transformer is designed for low
magnetizing current when under load, this large increase in magnetizing current will build up a
large flux in the magnetic circuit and cause the transformer to act as a step-up transformer,
inducing an excessively high voltage in the secondary when under no load.
The main use of using the earth switch (E/S) is to ground the extra voltage which may be
dangerous for any of the instrument in the substation.

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  Capacitor bank:
A capacitor bank is a grouping of
several
identical capacitors interconnected in
parallel or in series with one another.
These groups of capacitors are typically
used to correct or counteract undesirable
characteristics, such as power factor lag
or phase shifts inherent in alternating
current (AC) electrical power
supplies. Capacitor banks may also be
used in direct current (DC) power
supplies to increase stored energy and
improve the ripple current capacity of the power supply.

 Lightning cell
Periodical/Preventive maintenance, breakdown maintenance, shutdown maintenance and repair
of plant lighting system and street lighting system and security lighting system in plant area
(except coal handling plant) of GHTP Lehra Mohabbat. Including 220 KV switchyard, 220 KV
Transformer yard, 66 KV switchyard, 220 KV control room building, TG 0m to 15.5m floor,
P.R.D.S. 21 floor, boiler 0m to 52m floors, service building, DG set house, DM plant,
switchgears, RAWPH, ESP control room, electrical and mechanical workshop, cooling towers
110 m, chimneys 220 m, CW pump house and gas plant, canteen, dispensary, car/scooter stand,
fire station, O and M store offices, store sheds, ware house, oil tank area and FODPH.
1. Lighting fixtures.
2. Decorative industrial type tube lighting fixtures.
3. L.T. cables installed at plants, security towers, chimneys and for street lighting.
4. L.D.Bs installed for AC and DC supply circuits.
5. Internal electrical installation of various non-residential buildings at the plant.

24
 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:

Parameters 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

25
 Water Treatment

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: CLARIFIER

26
 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: DM PLANT OVER VIEW

Fig: % 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. 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.
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:

29
 Manufacturer Type : Bharat Forge Ltd., India
Type : HBS 3600-8
Hydraulic coupling:
Manufacturer : Voith Turbo GMBH and Co.
Type : R 16 K. 1
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

30
 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 journals + 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 : Duramen allice / Salol

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%)

31
 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.
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 2 nd pass. The
complete pressure parts are suspended from the boiler structural steel roof sections and arranged
for free expansion downward.

Fig: STEAM GENRATOR Fig: STEAM GENRETOR DETAIL DEGINE

32
 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.

33
 SUPERHEATER: Most of the modern boilers are having super heater and reheater
arrangement. Super heater 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

34
 is used to run the alternator, which is coupled to turbine, there by generating electrical
energy.

 ECONOMISER: Flue gases coming out of the boiler carry lot of heat. Function of
economizer 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
economizer 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 outside 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 nearby 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).

35
 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

36
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. Super heater 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 economizer : 243o C
10. Ambient air temperature : 40o C

37
 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. 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 Banca 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

38
generates rotary motion, it is particularly suited to be used to drive an electrical generator; about
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
thermodynamic 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

39
 • The Reheater reheats the steam from a temperature of 360°C back to 560°C

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. Modern steam turbine generator for a coal fired steam plant

40
 Fig. 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

41
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.
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. 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.

42
 b) VACUUM SYSTEM:

Fig: 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.
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

43
 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.

44
 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.

45
 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 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.

Fig. POWER GENERATOR ASSEMBELED WITH TERBINE

46
 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 meters to 450 meters. 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.

WORKING OF COOLING TOWER

47
 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.

 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 firefighting 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.
48
  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.

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.

 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.
 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:

49
 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 watercooler by
clear water.

H2 coolers : 350 m3 / hr

Turbine oil coolers : 3625 m3 / hr

Seal oil coolers : 130 m3 / hr

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

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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.

 HYDROGEN GAS COMPRESSER: Hydrogen Gas Compression is done by

recuperating 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
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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)

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 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
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.

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 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)

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 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 Tej Bansal in 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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