INTRODUCTIO

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

coal for four units based on specific fuel consumption of 0.60 kg / kWh. The conveying

and crushing system will have the same capacity as that of the unloading system. The

coal comes in as large pieces. This coal is fed to primary crushers, which reduce the size

of coal pieces from 400mm to 150mm. Then the coal is sent to secondary crusher through

forward conveyors where it is crushed from 150mm to 200mm as required at the mills.

Then the coal is sent to boilers with the help of primary fans. The coal is burnt in the

boiler. Boiler includes the pipes carrying water through them; heat produced from the

combustion of coal is used to convert water in pipes into steam. This steam generated is

used to run the turbine. When turbine rotates, the shaft of generator, which is

mechanically coupled to the shaft of turbine, gets rotated so, three phase electric supply is

produced.

The basic requirements are:-

♣ Fuel (coal)

♣ Boiler

♣ Steam turbine

♣ Generator

♣ Ash handling system

♣ Unit auxiliaries
 BRIEF HISTORY
OF
PLANT

Due to high rate of increasing population day by day, widening gap between power

demand and its availability was one the basic reason for envisaging the G.N.D.T.P.

for the state of Punjab. The other factors favoring the installation of the thermal

power station were low initial cost and comparatively less gestation period as

compared to hydro electric generating stations. The foundation stone of G.N.D.T.P.

at bathinda was laid on 19th November 1969, the auspicious occasion of 500th birth

anniversary of great Guru Nanak Dev Ji.

The historic town of bathinda was selected for this first and prestigious thermal

project of the state due to its good railway connections for fast transportations of coal,

availability of canal water and proximity to load center.

The total installed capacity of the power station 440MW with four units of

110MW each. The first unit of the plant was commissioned in September, 1974.

Subsequently second, third and fourth units started generation in September 1975, March

1978, and January 1979 respectively. The power available from this plant gives spin to

the wheels of industry and agricultural pumping sets.

 R&M WORKS AT
GNDTP,
BATHINDA

R&M of GNDTP unit 1&2 has already been completed pending PG Test. R&M works of
unit 3&4 is underway to improve performance, enhance capacity and extend operating
life of the units. The present status of R&M works of GNDTP units is as under:
Unit I&II: - Against approved project Report of Rs. 229 Crores, Order was placed on
M/S NASL, New Delhi for major R&M works on Turnkey basis at a total of Rs.183
Crores.
Unit II: R&M works completed in October, 2005 (Pending attending to some deficiencies
by the firm). Average PLF achieved post R&M works is 87%.
Unit I: - R&M works completed and taken for normal operation in May, 2007(Pending
attending to some deficiencies by the firm). Average PLF achieved post R&M during
May’07 and June ’07 is 95.65%.
Unit III & IV: - Order for executing R&M works on Turnkey basis already placed on
M/S BHEL at a total cost of Rs. 465.36 Crores. 10% advance payment has been made to
M/S BHEL on 22/12/2006 and design and drawing work is in progress. As per Schedule,
work is to be completed in a phased manner upto July 2009. Apart from enhancing the
operating life and performance level of the units, it is also planned to upgrade the
capacity from 110 MW to 120 MW each resulting in total capacity addition of 20 MW.
 SITE
SELECTION

The selection of site for Thermal Power Plant is more difficult compared to Hydro

Power Plant, as it involves number of factors to be considered for its economic

justification. The following consideration should be examined in detail before selection

of the site for the Plant. The location for plant should be made with full consideration not

only of the trends in the development and location but also the availability and location of

the cheapest source of primary energy:-

 Availability of fuel

 Ash disposal facilities

 Space requirement

 Nature of land

 Availability of labour

 Transport facilities

 Public society problems

 Development of Backward Area

 LANDMARK
ACHIEVED

 G.N.D.T.P. won an award of Rs. 3.16 crores from Govt. of India for better

performance in 1983-84.

 It achieved a rare distinction of scoring hart Rick by winning meritorious

productivity awards of Govt. of India, Ministry of Energy for year 1987, 1988 and

1989 due to its better performance.

 It again won meritorious productivity awards during the year 1992-1993 and

1993-94 and has become entitled for the year 1996-1997 for better performance.

 It also won awards for reduction in fuel oil consumption under Govt. of India

incentive scheme years from 1992-1993 (awards money for 1992, 1993 and 1994

already released for 1995, 1996 and 1997 under the consideration of Govt. of

India).

 G.N.D.T.P. had achieved a generation of 2724240 LU’s (at a PLf of 70%) and

registering an oil consumption as low as 1.76ml/kwh during the year 1993-94 has

broken all previous records of performance since the inception of plant.

 CONTRIBUTION
OF
THE PLANT

Guru Nanak Dev Thermal Plant, Bathinda, in addition to indirect contribution in various

facts of state economy, is also responsible for:-

♣ Narrowing the gap between power demand and power availability of the state.

♣ Providing employment potentials to thousands of workers.

♣ Covering the backward surrounding area into fully developed Industrial

Township.

♣ Providing additional relief to agricultural pumping sets to meet the irrigation

needs for enhancing the agriculture production.

♣ Reliability and improvement in continuity of supply and system voltage.

♣ Achieving cent percent rural electrification of the state.

 PLANT SALIENT
FEATURES
THE PLANT

PROJECT AREA:-

Power plant 238 acres

Ash disposal 845

Lake 180

Residential colony 285

Marshalling yard 256

Total area 1804

TOTAL COST: - Rs. 115 crores

STATION CAPACITY: - four units of 110MW.each

BOILER:-

Manufacturers B.H.E.L.

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

Superheater outlet pressure 139 kg/cm²

Reheater outlet pressure 33.8 kg/cm²

Final superheater/reheater temperature 540°C

Feed water temperature 240°C

Efficiency 86%
Coal consumption per day per unit 1400 tones (Approximate)

STEAM TURBINE:-

Manufacturers B.H.E.L.

Rated output 110 MW.

Rated speed 3000 r.p.m.

Number of cylinders three

Rated pressure 130 kg/cm²

Rated temperature 535°C

Condenser vacuum 0.9 kg/cm²

GENERATOR:-

Manufacturers B.H.E.L.
Rated output
(Unit- 1 & 2) 125000KVA
(Unit -3 & 4) 137000KVA
Generator voltage 11000 volts
Rated phase current
(unit –1 & 2) 6560 Amps.
(unit –3 & 4) 7220 Amps.
Generator cooling hydrogen
BOILER FEED PUMPS:-

Number per unit two of 100% duty each

Type centrifugal

Rated discharge 445 T/hr.

Discharge head 1960 MWC.

Speed 4500 r.p.m.

CIRCULATING WATER PUMPS:-

Numbers for two units five of 50% duty each

Type mixed flow

Rated discharge 8600 T/hr.

Discharge head 24 MWC.

COOLING TOWERS:-

Numbers four

Water cooled 18000 T/hr.

Cooling range 10°C

Height 120/12 metres

COAL PULVERISING MILLS:-

Numbers three per unit

Type drum-ball

Rated output 27 T/hr.

Coal bunkers 16 per unit

RATING OF 6.6 KV AUXILLIARY MOTORS:-

Coal mill 630 KW

Vapour fan 320 KW

C.W. Fan 800/746 KW

Coal crusher 520 KW

Primary air fan 320 KW

Forced draught fan 320 KW

Boiler feed pump 3500 KW

Induced draught fan 900/1000 KW

Condensate pump 175 KW

 WORKING OF
THERMAL
PLANT

Coal received from collieries in the rail wagon is mechanically unloaded by

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

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

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

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

BOILER FEED PUMP:-

As the heart is to human body, so is the boiler feed pump to the steam power plant. It is
used for recycling feed water into the boiler at a high pressure for reconversion into
steam. Two nos. 100% duty, barrel design, horizontal, centrifugal multistage feed pumps
with hydraulic coupling are provided for each unit. This is the largest auxiliary of the
power plant driven by 3500 KW electric motor.
The capacity of each boiler at GURU NANAK DEV THERMAL PLANT is
375 tones/hr. The pump which supplies feed water to the boiler is named as boiler feed
pump. This is the largest auxiliary in the unit with 100% capacity which takes suction of
feed water from feed water tank and supplies to the boiler drum after preheating the same
in HP-1, HP-2 and economizer. The delivery capacity of each boiler feed pump is 445
tones/hr. to meet better requirements corresponding to the various loads, to control steam
temperature, boiler make up water etc. The detailed particulars checking of protections
and inter locks, starting permission etc. are as below:-

Particulars of BFP and its main motor:-

 BOILER FEED PUMP: - The 110 MW turboset is provided with two boiler feed
pumps, each of 100% of total quantity. It is of barrel design and is of horizontal
arrangement, driven by an electric motor through a hydraulic coupling.
Type 200 KHI
No. of stages 6
Delivery capacity 445 t/hr.
Feed water temperature 158°C
Speed 4500 rpm
Pressure at suction 8.30 kg/cm²
Stuffing box mechanical seal
 Lubrication of pump by oil under pressure
And motor bearing supplied by hydraulic coupling
Consumption of cooling water 230 L/min.
WATER TREATMENT PLANT:-
The water before it can be used in the boiler has to be chemically treated, since untreated
water results in scale formation in the boiler tubes especially at high pressure and
temperatures. The water is demineralised by Ion Exchange Process. The water treatment
plant has production capacity of 1800 Tonnes per day for meeting the make-up water
requirement of the power station.

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

INDUCED DRAUGHT FAN:-

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

CONTROL ROOM:-
The control room is the operational nerve center of the power plant. The performance of
all the equipments of the plant is constantly monitored here with the help of sophisticated
instrumentation and controllers. Any adverse deviation in the parameters of various
systems is immediately indicated by visual and audio warning and suitable corrective
action is taken, accordingly. The control room is air conditioned to maintain the desired
temperature for proper functioning of the instruments.
SWITCH YARD:-
Electricity generated at 11 KV by the turbo-set is stepped-up by unit transformers to
132/220 KV for further transmission through high tension lines to Maur, Muktsar,
Malout, N.F.L., Sangrur and Ludhiana. Transmission of power to grid is controlled
through 7 nos. 220 KV and 15 nos. 132 KV. Air Blast Circuit Breakers along with their
associated protective systems.

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

CRUSHER HOUSE:-
Coal unloaded by the wagon tippler is carried to crusher house through conveyors for
crushing. Two nos. hammer type coal crushers are provided, which can crush coal to a
size of 10 mm. The crushed coal is then supplied to Boiler Raw Coal Bunkers. The
surplus coal is carried to coal storage area by series of conveyors. Crushing of coal is an
essential requirement for its optimum pulverizing and safe storage.

COOLING TOWERS:-
Cooling Towers of the power plant are the land mark of the Bathinda City even for a far
distance of 8-10 kilometers. One cooling tower is provided for each unit for cooling
18000 tones of water per hour by 10°C. cooling towers are massive Ferro-concrete
structure having hyperbolic profile creating natural draught of air responsible for
achieving the cooling effect. Cooling tower is as high as 40 storey building.
BOILER:-
It is a single drum, balanced draught, natural circulation, reheat type, vertical combustion
chamber consists of seamless steel tubes on all its sides through which water circulates
and is converted into steam with the combustion of fuel. The temperature inside the
furnace where the fuel is burnt is of the order of 1500°C. The entire boiler structure is of
42meter height.

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

CIRCULATING WATER PUMP:-

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

Since G.N.D.T.P. units are primarily coal fired units so each boiler is
provided with closed milling circuits to pulverize the raw coal which is
received from coal conveying system after coal crushes before it is fired in
the furnace. The necessity of pulverizing the coal is to be ensuring its
maximum possible combustion in the furnace. The coal data for units are: -

COAL DATA UNITS 1 & 2 UNITS 3 & 4

Type of Coal Bituminous Bituminous

Net Calorific Value 4300 Kcal/kg 4727 Kcal/Kg

Moisture 10 % 7.5 %

Ash Content 30 % 32 %

Volatile Matter 24 % 27 %
Incombustible

Inlet of Coal 10 mm 20 mm

Raw coal of maximum size 10 mm – 20 mm is pulverized in the milling

circuit and the output from the mill is fine coal. Milling circuits of the
following main constituents: -
1. Raw Coal Bunkers (R.C. Bunkers).

2. Raw Coal Chain Feeders.

3. Drum Mill or Coal Mill.

4. Classifiers.

5. Cyclone Separator.

6. Vapour Fan.

7. Pulverized Coal Bunkers (P.C. Bunkers).

COAL MILL
RAW COAL BUNKER:-
Each of three raw coal bunkers is fabricated from the sheet metal and is well stiffened all
around. The storage capacity of each raw coal bunker is about 500 tones. There are four
outlet gates with each bunker. The gates are electrically operated from site. In case of
failure of the electric motors the gate can be hand operated from site. At a time only one
gate opening is suffices but should be changed so that there is no pilling within the
bunker.

RAW COAL CHAIN FEEDER:-

The raw coal chain feeder transports coal from raw coal bunker to the inlet chute leading
to the pulverized/coal mills. There is a double link chain of high tensile strength steel,
which moves on wheels and sweeps the raw coal falling over the top of the raw coal
chute of the mill. The height of the coal bed in the chain feeder can be adjusted manually
by means of lever operated damper. The maximum and minimum heights of the coal bed
are 200mm and 120mm respectively. The signaling equipment indicates the absence of
coal flow in the feeder, which is annunciated in the unit control board (U.C.B.). The main
shaft on the driving end is connected to the driving unit, consisting of variator, a gear box
and a motor all mounted as a single unit. The chain wheel on the driving end shaft is
provided with a shear pin, which will shear off and disconnect the driving mechanism if
there is any overload on the feeder. The speed of the chain feeder is regulated
automatically/remotely by actuating the control spindle of the variator through a
servomotor. A pump for circulating the oil in the gear box of variator is an integral part of
variator driven by a separator motor. Some of the technical data about the raw coal chain
feeder is given here:-
1. Output of the chain feeder 10-45 tonnes/hr.
2. Speed variations 0.0503-0.151m/sec.
3. Main motor 7.5kW, 415V, 50Hz.
4. Oil pump motor 0.05kW, 220V
5. Operating motor of each gate 3HP, 415V and 50Hz.
DRUM MILL:-
Each mill consists of single compartment drum, bearings driving motor, coal inlet
and discharge piping, ball change and lubricating equipment for mill bearings. Mill drum
is fabricated from thick steel plates and is supported on to the anti-friction bearings. The
mill is driven by an electric motor of capacity 630kW, 990 rpm, 6.6kV through a
reduction gear, which reduces the speed to 17.5 rpm. The ball charge for the mill consists
of the three different sizes of forged steel balls detailed as below. The capacity of each
mill is 27 T/hr. in case of unit 1 & 2 and 28 T/hr.
1. 40mm diameter 22500 kg
2. 50mm diameter 20000kg
3. 60mm diameter 10000kg
4. Total Ball Charge 52500kg

During operation only 60mm diameter balls are added is approx. 500 kg per week
and the guiding factor is the amperage of the coal mill, normally it should be 66-ampere
approx. at full load and when it falls below the above value ball charging of the mill is
carried out. Lubricating system consists of the oil tank, gear pump, oil cooler and base
frame to mount all these equipments. Gear pump is driven by an electric motor of rating 1
H.P., 415 V, 1440 rpm. Suction side of the gear pump is connected to the tube oil tank
and the delivery side is connected to inlet of the oil cooler and after cooling oil goes to
the bearings. The oil from the bearings is cooled to the required temperature in the cooler
by the means of plant bearing cooler water.

CLASSIFIER:-
The classifier is fabricated from the steel plates. It is an equipment that separates fine
pulverized coal from the coarser pieces. The pulverized coal along with the carrying as
well as drying medium (flue gas) strikes the impact plate in the classifier and the coarser
pieces get separated due to the change in the direction of flow and go back to mill. The
stream then passes to the outlet branch of the classifier through an adjustable telescopic
tube. At the outlet adjustable vanes are provided to change the size of coal when required.
CYCLONE SEPARATOR:-
The centrifugal type cyclone separator consists of two cyclones made up of welded
sheets. It is equipment in the milling plant, which serves for separating the pulverized
coal from the vapours i.e. carrying medium. The pulverized coal gets stored in the
pulverized coal bunkers and vapours go to suction of vapour fan. At the bottom of the
cyclone separator a rotary valve (Turnikete) is provided to transport coal from cyclone
separator to P.C. bunker on the worm conveyor as the case may be.

VAPOUR FAN:-
Pulverized coal bunker is welded from thick steel sheets and has a capacity of 4 hours
coal consumption at maximum continuous rating of the boiler. The whole bunker is
insulated externally. The carbon-dioxide blanketing system has been provided in the P.C.
bunker to prevent fire hazards inside the bunker. The while storage bunker is divide into
four parts namely A, B C & D. Further four coal feeders are taken out from each bunker
leading to each corner of the furnace.

CRUSHING OF COAL:-
When coal reaches the plant, normal size of coal is about 500mm. After unloading the
coal from the rake is fed to primary crusher, which reduces the size to 120mm. Then coal
is fed to secondary crusher which reduces the size to 25mm and this coal goes to bunker
with the help of conveyor belt from where coal finally goes to coal mill where coal is
transferred in form of pulverized coal. The coal is heated with the help of hot primary air.
We maintain the temperature of about 70°C in coal mill. This temperature is maintained
with the help of cold air and a hot air damper.

USE OF OIL:-
Before the coal reaches the furnace, we preheat the furnace in order to remove the
moisture and raise the temperature of furnace, so that coal can catch fire easily without
any delay. This preheating of furnace is done with the help of oil. With burning of oil, we
maintain the temperature of furnace at 350°C. we cut the oil supply after 350°C because
oil is very costly. Source of oil for G.N.D.T.P., Bathinda is Mathura Oil Refinery. Other
use of oil is in bearing system for cooling. There are large number of bearings for plant.
For example bearing system of turbine. These bearings get heated upto high temperature,
which is dangerous. So we cool the bearing by circulating water in bearing.

COAL FEEDING AND COAL MILL:-

From the coal handling plant, coal comes in two belts namely 5A and 5B and then by
belts 6A and 6B coal comes in bunkers. Bunker capacity is 300 tonnes. Number of outlets
of bunker is three. First gate is opened for one hour and second and then third. If open the
one gate for long time, then coal will stop going to mill. That is why we open the gate
turn by turn.

RAW COAL CHAIN FEEDER:-

Raw coal chain feeder is just below raw coal bunker. It is a sliding chain which feed the
coal to mill. We can change the quantity of coal which is fed to mill in two ways.

 By changing the speed of chain

 By changing the depth of coal in chain

Speed of chain can be changed by adding a gear system to motor. We connect the
gear system with motor with a pin called shear pin. The prevent the overloading of motor
because when the coal quantity of coal on chain is greater than its capacity then the pin
will break and prevent the pin from overloading. Speed of Raw Coal chain is 2” to 6”/sec.

COAL MILL:-
These are mainly of two types:-
i) Ball Mills
ii) Bowl Mills

Ball Mills: - In Ball Mills there are steel balls which are revolving in horizontal
cylindrical drum. These balls are free from any shaft and balls are touching with each
other and with internal body of drum. These types of mills are at Bathinda Thermal Plant.
On the other hand, bowl mills part of the mill contain drive system i.e. it contains 6.6 kV
electric motor and gear system which translates the revolution about horizontal axis to
revolve about vertical axis. The revolving vertical axis contains a bowl about the driving
system. This bowl is fixed with driving and revolving with shaft. There are also three
rollers which are suspended at some inclination, so that there is a gap of few mm between
roller surface. These rollers are free to rotate about the axis.

Bowl Mills: - The coal is grinded and then fed into the mill at the center or near of
revolving bowl. It passes between the grinding ring in revolving bowl and rolls as
centrifugal force causes the material to travel towards the out perimeter of bowl. The
springs, which load the rolls, impart the necessary force for grinding. The partially
pulverized coal continue going up and down and over the edge of bowl.
 COAL HANDLING
PLANT
(CHP)

The G.N.D.T.P. units are primarily coal-fired units and the coal consumption at
maximum continuous rating (M.C.R.) per unit is about 58 T/Hr. the coal used at
G.N.D.T.P. is of bituminous and sub-bituminous type and this is received from some
collieries of M.P. and Bihar. The designed composition of coal is as below:-

 Type Bituminous Coal

 Net calorific value 4300 kcal/kg
 Moisture content in coal 10%
 Ash content 30%
 Volatile matter in combustibles 24%
 Grind ability index 50 Hard Groove

The coal handling plant at G.N.D.T.P. has been supplied and erected by M/s
Elecon Engineering Company Limited, Vallabh Vidya Nagar, Gugarat. Coal is
transported from the coal mines to the plant site by Railways. Generally, the raw coal
comes by railway wagons of either eight wheels weighing about 75 to 80 tones each or
four wheels weighing about 35 to 40 tones each. The loaded wagon rake is brought by
railways main line loco and left on one of the loaded wagon tracks in the power station
marshalling yard. The main line loco escapes through the engine track. The station
marshalling yard is provided with 8 tracks. The arrangement of the tracks in the
marshalling yard is as follows:-

DESTINATION NO. OF TRACKS

Loaded wagons receiving tracks Four
Empty wagon standing tracks Three
Engine escape tracks One
UNLOADING OF COAL:-
In order to unload coal from the wagons, two Roadside Tipplers of Elecon make
are provided. Each is capable of unloading 12 open type of wagons per hour. Normally
one tippler will be in operation while the other will be standby. The loaded wagons are
brought to the tippler side by the loco shunters. Then with the help of inhaul beetle one
wagon is brought on the tippler table. The wagon is then tilted upside down and emptied
in the hopper down below. The emptied wagon comes back to the tippler table and the
outhaul beetle handles the empty wagons on the discharge side of the tippler. The tippler
is equipped with the integral weighbridge machine. This machine consists of a set of
weighing levers centrally disposed relative to tippler. The rail platform rests on the
weighing girders and free from rest of the tippler when the wagon is being weighed. After
weighing the loaded wagons is tipped and returned empty to the weighing girders and
again weighed. Thus the difference of the gross weight and the tare weight gives the
weight of the wagon contents. The tipplers are run by motors of 80 H.P. each through
gears only.

WAGON TIPPLER

The tippler is designed to work on the following cycle of operation:-

Tipping 90 seconds
Pause 5-12 seconds
Return 90 secondS
Weighing 30 seconds
Total 215-222 seconds

Allowing 85 seconds for wagon changing it will be seen that 12 eight-wheel wagons or
24 four-wheel wagons per hours can be tipped. However since the coal carrying capacity
is 500 tones per hour load of 12 wagons comes to 8 to 9 per hour.

DUST TRAPPING SYSTEM:-

The tippler is also provided with the dust trapping systems by which the dust nuisance
will be minimized. As the tippler rotates, a normally closed hopper valve opens
automatically and the discharged material passes through it into the hopper with its dust-
setting chamber, there is an air valve of large area, which opens, simultaneously with the
hopper valve. The object of this air valve is to blow back through the hopper valve into
the tipping chamber, which must occur if, the settling chamber were closed, it being
remembered that a large wagon contains some 240 cubic feet of material and that this
volume of dust air would be forced back at each tip if the hopper chamber were a “closed
bottle”. The air valve and the hopper valve are shut immediately on reversal of the tippler
and are kept shut at all times except during the actual discharge. The hopper valve is
operated by a motor of 10 H.P., 415 Volts and the air valve is operated by electro-
hydraulic thruster. Inlet valve consists of large number of plates sliding under the wagon
tippler grating. Coal in the wagon tippler hopper forms the heap and as such obstructs the
movement of sliding valve and damaging the plates. The inlet and outlet valves have
therefore been bypassed.
The unloaded material falls into the wagon tippler hopper (common to both
tipplers) having a capacity of 210 tones. The hopper has been provided with a grating of
300mm X 300mm size at the top so as to large size boulders getting into the coal stream.
There is also a provision of unloading the wagons manually into the MANUALLY
UNLOADED HOPPER of 110 tones capacity. Manually unloading will be restored to
while unloading coal from sick wagons or closed wagons.
MAGNETIC PULLEYS:-
On belt conveyor no. 4A and 4B, there have been provided high intensity
electromagnetic pulleys for separating out tramp iron particles/pieces from the main
stream of coal conveying. D.C. supply for the magnet is taken on 415 volt, 3 phase, 50
cycles A.C. supply system.
In addition to above high intensity suspension type electromagnets have also been
provided on belt conveyors 4A and 4B for separating out tramp iron pieces/particles.

RECLAIMING:-
If the receipt of coal on any day more than the requirement of the boilers, the
balanced material will be stocked via conveyor 7Aand 7B and through telescopic chute
fitted at the end of the conveyor. At the end of the chute one tele level switch is provided,
which automatically lifts the telescopic chute to a predetermined height every time. The
tele level switch is actuated by the coal pile. When the telescopic chute reaches maximum
height during operation, which will be cut off by limit, switch and stop the conveying
system. When the pile under the telescopic chute is cleared, the telescopic chute can be
independently lower manually by push buttons.

There are five bulldozers to spread and compact the coal pile. Bulldozers of Bharat Earth
Movers Limited Make are fitted with 250 H.P. diesel engines. Each bulldozer is able to
spread the crushed coal at the rate of 250 tones/hr. over a load distance of 60m the coal
can be stacked to a height of 6m the stockpile stores coal for about 45 days for four units
with an annual load factor of 0.66.
Whenever coal is to be reclaimed the bulldozers are employed to push the coal in
the reclaim hopper having a capacity of 110 tones. The coal from the reclaim hopper is
fed either 9A or 9B belt conveyor through vibratory feeders 8A and 8B.

CRUSHER HOUSE:-
The crusher house accommodates the discharge ends of the conveyor 4A, 4B receiving

ends of conveyor 5A, 5B and conveyor 7A and 7B, two crushers, vibrating feeders and

necessary chute work. There are two crushers each driven by 700H.P. electric motor, 3
phase, 50 cycles and 6.6 kV supply. The maximum size of the crushed coal is 10mm. The

capacity of each crusher is 500 tones/hr. one crusher works at a time and the other is

standby. From the crusher the coal can be fed either to the conveyors 5A, 5B or 7A, 7B

by adjusting the flap provided for this purpose. There is built in arrangement of bypassing

the crusher by which the coal can be fed directly to the conveyors bypassing crusher.

CONVEYOR BELT AND CRUSHER HOUSE

Boiler section
The steam generating unit is designed to meet the nominal requirements of 110MW turbo
generator set. The unit is designed for a maximum continuous rating of 375 tones/hr. at a
pressure of 139kg/cm2 and a steam temperature of 5400°C. the reheated steam flows at
MCR 32H tones/hr. at the feed water temp at MCR is 2400°C. The unit is a balance
draught dry bottom; single drum natural circulation, vertical water tube type, construction
with skin casing and a single reheat system. The furnace is arranged for dry ash discharge
and is fitted with burners located at the four corners. Each corner burner comprises coal,
vapour oil and secondary air compartments. The unit is provided with three ball mills and
arranged to operate with intermediate cool powder bunker. The steam super heater
consists of 4 stages Viz. Ceiling, convection, platen and final superheated. The ceiling
super heated forms the roof of the furnace and horizontal pass and finishes as the rear
wall of the second pass. The convection super heated is made up of horizontal banks
located in the second pass. While the platens are located at the furnace exit, the portion
above the furnace nose encloses the final superheated reheater are in two stages, first
stage is the triflux heat exchangers located in the second pass, which absorbs heat from
superheated steam as well as from the flue gases. The second stage is exit reheater
located in the horizontal pass as pendant tubular loops.
(a) The flue gas for drying the cool in the mills is tapped off after the triflux heat
exchangers. The damper located in the hot flue gases pipe leading to mill controls the
quantity. Control the circulating vapour of the mill entry effect temperature control.
Immediately after the triflux heat exchanger, the air heaters and economizers are located.
The air heater is in 2 stages.
(b) The hot air for combustion from air heater stage 2 is led into the common wind box
located on the sided of the furnace. 4 cool air mixed pipes from pulverized coal bounders
are connected to 4 cool burners’ nozzle at the corners. There will be totally 16 coal
nozzles. 4 located in each corner. Oil guns will be located in the secondary air nozzle for
coal burning. The turn down ratio of the guns will be so selected that it will be possible to
use them also for pulverized fuels flame stabilization while operating under load below
the control point.
(c) Take into consideration the high % age of ash and the relatively poor quality of coal
due regards has been paid to wide pitching the tubes and to the gas velocity across the
heating surface areas. In order to insure reliable and continuous operation sample sot
blowing equipment is provided. There are short retractable steam root blowers provide at
the top of furnace fully retractable rotary type blowers are located for cleaning of the
secondary super heater and final heater partly retractable steam blowers are arranged for
the horizontal reheater and super heaters in the second pass. The steam root blowers are
electrically operated.
(d) Root blowing nozzles using blow down from boilers drum are provide for the
cleaning of areas around the burners nozzles zone for dislodging of slag boulder if any in
the bottom ash hopper in the furnace.
(e) Two FD fans are provided per boiler. The FD fans are of the axial type driven by
constant speed motor. The regulation of quantity and pressure is done by inlet vane
control. The flue gases are sucked through the mechanical and electrostatic precipitators
by I.D. fans and delivered into the chimney. Two I.D. fans are provided for each boiler
and they are of the axial type driven by constant speed motors. Inlet vane control effects
the capacity change with reference to load. Both the I.D. and FD fans have been
dimensioned taking into account the minimum margins of 15% on volume and 32% on
pressure.
Specification

• Manufacturer B.H.E.L
• Maximum continuous rating 375tones/hr.
• Super heater outlet pressure 139kg /cm2
• Reheater outlet pressure 33.8 kg/cm2
• Final super heater temperature 540 deg.c
• Feed water temperature 240deg.c
• Efficiency 86% (stage-1)
87% (stage-2)

• Coal consumption per day 1500 tones

ASH SYSTEM
BOTTOM ASH SYSTEM
The ash deposited at the bottom of the furnace is collected in a water impounded hopper
where a continuous flow of water is maintained to limit the temperature of ash inside the
hopper. The bottom ash cleaning is done in every cycle of 8 hours. The bottom ash
system is local manually operated. On opening of feed gate ash is allowed to discharge
into a double roll linder grinder where it is grounded to smaller size, which can be
transported through the pipe line below the linker grinder there is a venturi which sucks

the ground ash the vaccum created at the venturi throat by the flow of high pressure water
tapped. Dawn stream of the discharge of the ash water pumps. The pressure recovered at
the end of venturi is adequate to convey the slurry to disposal area.

STEAM CYCLE

The design of the power cycle based on the modern concept, where a unit consists of a
steam generator with its independent firing system tied to the steam generation. The
steam generator is designed for maximum continuous rating of 375-tonnes/hr. and steam
Pressure of 139-kg/cm2 at temperature of 540°C respectively. The steam generator is
designed to supply to a single reheat type condensing steam turbine with a 8 non
regulated extraction points of steam for heading the condensate and feed water. The
steam cycle can be classified into the following three divisions: -

a. Main steam (b) Reheat steam (c) extraction steam

(a)MAIN STEAM

Saturated steam from the steam generator drum is led to the super heater bank to heat if
up to 540°C saturated steam from the drum is led to the ceiling super hearter (between
SHH1 and SHH2) from ceiling super steam goes to convection super heater (between
SHH2 and SHH3) the first regulated infection for at temperature takes place after
convection super heater (between SHH9 and SHH10). Before entry to final super heater
the steam is again at temperature by regulated injection. The steam is coming out from
the final super heater normally at a pressure of 139 kg/cm2
Temperature takes place after convection super heater (between SHH9 and SHH10).
Before entry to final super heater the steam is again at temperature by regulated injection.
The steam is coming out from the final super heater normally at a pressure of 139 kg/cm2
at a temperature of 540oC. This steam is feed to the control valve. In each of the two live
steam lines there is one turbine side main steam stop valve and one high pressure quick
closing valve along with two control valves.

(b) EXTRACTION STEAM

Steam for heating of the condenser and the feed steam is extracted from 8 non regulated
extraction points from the turbine. Heating is carried out in five stages of L.P. heaters,
one deareating heater and in two H.P. heaters extraction 1,2,3, is taken from L.P. turbine.
Extraction 4, 5, 6 and 7 are taken from M.P. turbine. Extraction 8 is obtained from C.R.H.
line first and second stage of heating is done by two sets of twin low-pressure heaters
mounted directly in the L.P. casing of the turbine. Extraction 3,4 and 5 are connected to

the deaereating heater placed above feed water storage tank 7th and 8th extraction steam is
fed to the vertical H.P. heaters respectively.

(C) REHEAT STEAM

Exit steam from the H.P. turbine is taken back to the reheater section of the steam
generating unit. Reheating is done in two stages both by flue gas and by super heated
steam. The steam to be reheated is first pass through the triple-heated exchanger, where
super heated steam is used as the heating media. The steam is finally reheated in final
reheaters (RHH3) RHH4 and RHH5) suspended in the horizontal pass of the furnace.
Reheat steam at a normal pressure of 36.4 kg/cm2 at a temperature of 540°C respectively
is fed to the M.P. cylinder by two hot reheat steam pipes through strainers and combined
stop and interceptor valves. In each of the cold reheat steam lines from H.P. cylinder a
non-return valve is operated by oil pressure is provided.

MILLING CIRCUIT

The crushers crush the coal upto the dia of 20 mm. This coal comes to the raw coal
bunker through conveyer belts. This coal is fed into the ball mill through chain feeder,
operated by motor. In drum the steel balls are used to make it pulverized. At one end coal
enters the mill and from the other end pulverized coal is sucked by vapour fan. The
pulverized coal is used for burning in the furnace. On its way the p.c. (pulverized coal)
bunker, it goes from classifier and cyclone separator function of classifier is to use the
coal for burning coal which could not pass the classifier, is collected on the gravity
damper. When the weight of this coal is enough, gravity damper is opened because of the
weight of the coal and this coal goes back to mill through run back piping and is further
pulverized. In cyclone separator much finer particles of coal is stored in P.C. bunker
because of centrifugal force. This coal is fed to the P.C. bunker through the warm feeder.
Through warm feeder, we can collect the pulverized coal in any of the P.C. bunker.
Warm feeder runs with the help of motor and gearbox.

COAL PULVERIZING MILL

Coal mill pulverizes the raw coal into a fine powder before it is burnt in the boiler
furnace. The pulverizing of coal is achieved with the impact of falling steel balls,
weighing 52.5 tones contained in the mill drum rotating at a slow speed of 17.5 rpm. The
raw coal is dried before pulverizing with inert hot flue gases tapped from the boiler.
Three coal mills each having a pulverizing capacity of 27 tones per hours are provided
for one unit.

Specification

Numbers Three per unit

Type Drum ball

Rated output 30-32 tonnes/hr.

TURBINE SECTION
The turbine is the prime mover for the generator in the power plant Different
types of steam turbines used in thermal power plants, but the ones. Which
are used at G.N.D.T. P. are categorized as follows

S.No. Type of Turbine Turbine at G.N.D.T.P.

1. Horizontal/vertical Horizontal

2. Single/multi cylinder Multi cylinder

3. Condensing/non condensing condensing

4. Reheat/ non-reheat Reheat

5. Regenerative/non regenerative Regenerative

6. With by pas/without by pass with by pass (stage-1)

Without by pass (stage-2)

BASIC WORKING OF TURBINE

First of all the turbine is run on gear motor with the help of exciter. At that
time steam is kept on recirculating with the help of by pass valve. When the
pressure of steam is increased to on optimum level and turbine acquires a
particular rpm then steam is introduced in the H.P. (high-pressure) cylinder
first. The temperature of steam at entrance is 540°C and pressure is about
139 Kg/cm2. After doing its work on the H.P. Turbine, the steam is taken out
for reheating rated temperature of steam at reheater inlet is 360°C. The
temperature of steam is increased upto 535°C in the boiler shell and steam is
again introduced in M.P (Medium pressure) turbine. After M.P.turbine, the
steam is passed on to L.P. (Low-pressure) turbine. This process helps the
turbine to reach the speed of 3000 rpm. After L.P. turbine, the steam is
condensed in condenser, build below the turbine unit. The condenser
contains a number of brass tubes through which cooling out from L.P.
turbine it comes in contact with colder brass tubes then steam get
transformed into water. This water get collected in HOT WELL just below
the condenser. From here the hot water is again pumped with the help of
condensate pumps. The cooling water is used to condense steam gets heated
up and is cooled by falling from cooling tower. This completes the
processing of steam through turbine and condenser.

ROTOR OF TURBINE

All the rotors are manually by means of rigid coupling, including the rotors
of the generator. The speed of whole system of rotor lies in the following
ranges of the speed at the operating conditions: -

1900 to 2000 rpm Best noticed on the M.P. and L.P. rotors and generators.

2350 rpm Best noticed on H.P. rotor.

1. BEARING OF ROTORS

The axial load of the entire system of rotors is taken up by a double-sided

axial bearing located in the bearing stand between the H.P. and M.P casing.

These are two protections mounted near the axial bearing one hydro

chemical and one electromagnetic, which fouls the turboset during the non-

permissible movement of the rotor.

The rotors are placed on radial bearing which are machined to elliptical

shape. Further scrapping operations or change top and side clearances and

change in temperature of oil, influence the oil wedge and the position of the

journal bearing to maintain the same condition as existed during the initial

assembly.

In the lower half of bearing a hollow groove is provided in the babbit metal

through which oil the supplied through a drilled hole through H.P. jacking

oil pumps.

The high-pressure oil rotors are lifted in the bearing so that any scrapping of

the bearing is prevented.

2. TURBINE CASING

The high-pressure part of turbine is consisted of two-concentric horizontal

casing. Inner casing is connected in such a way to the other casing that it

enables to expand in all direction. The nozzles are attached to the inner

casing. The steam pipe is connected to the condensers and the condensers

are supported by springs. The casings are inter connected by the system of

guide keys through bearing pedestals in such a way that thermal expansion

of casing does not destroy the various parts of turbine.

The displacement-bearing pedestal between M.P. and H.P parts is measured

by the electromagnetic pick up. This valve is about of 15 mm to prevent

deformation at the casing. It is very important that sliding part clean

lubricated and free from hazard for connecting parts bolts elements. The

heating of bolts before tightening up and before the locking presents. The

flanges of M.P. and H.P. casings are designed to heat up by steam during the

starting up of turbo boost by which the difference in temperature between

the cylindrical position of the casing flanges and connected bolts is reduced

to limited deformation. The thermo couples are used for measuring

temperatures. The thermo couple is partially connected to the indicated

apparatus. Cooling fluid is generally used for reducing the temperature of

various parts.
3. REGULATION AND SAFETY EQUIPMENT FOR TURBINE

GOVERNING

The quality of steam entering in the turbine is regulated by the four

governing valves on the inlet to the M.P. part. The amount of opening at any
instant of these valves is controlled by the pressure of secondary oil, which
is indirectly depending on the primary oil pressure and directly depending
upon the spring force in the transformer during the stand still and during
starting of the turbo set. The pressure of primary oil is directly depending on
the speed of the set through the speed-sensing element. Operating the speed
changer or the normal speed changer can very the tension in the spring in the
transformer.

Thus make it possible to vary the speed before synchronizing. In case break
down of any equipment of the block the quick closing devices are provided
in the regulation system of the turbo set. H.P. quick closing valves
(H.P.Q.C) M.P. quick closing valves (M.P.Q.C) at return flap valves are
operated by either directly by the tripling lever or through the relay magnet
on the main relay which creates instantaneously loss of pressure of the quick
closing oil by the change of flow of oil inside the relay.

Distribution is used for checking the function of H.P.Q.C and M.P.Q.C

valves. The H.P. and M.P quick closing valves, the non return flaps and non
return extraction valves during normal operating condition have only two
positions one is fully opened another fully closed.

4. STEAM CYCLE

The design of the power cycle based on the modern concept, where a unit
consists of a steam generator with its independent firing system tied to the
steam generation. The steam generator is designed for maximum continuous
rating of 375-tonnes/hr. and steam Pressure of 139-kg/cm2 at temperature of
540°C respectively. The steam generator is designed to supply to a single
reheat type condensing steam turbine with a 8 non regulated extraction
points of steam for heading the condensate and feed water. The steam cycle
can be classified into the following three divisions: -

(a) Main steam (b) Reheat steam (c) extraction steam

(a) MAIN STEAM

Saturated steam from the steam generator drum is led to the super heater
bank to heat if up to 540°C saturated steam from the drum is led to the
ceiling super hearter (between SHH1 and SHH2) from ceiling super steam
goes to convection
Super heater (between SHH2 and SHH3) the first regulated infection for at
temperature takes place after convection super heater (between SHH9 and
SHH10). Before entry to final super heater the steam is again at temperature
by regulated injection. The steam is coming out from the final super heater
normally at a pressure of 139 kg/cm2 at a temperature of 540oC. This steam
is feed to the control valve. In each of the two live steam lines there is one
turbine side main steam stop valve and one high pressure quick closing
valve along with two control valves.

(b) EXTRACTION STEAM

Steam for heating of the condenser and the feed steam is extracted from 8
non regulated extraction points from the turbine. Heating is carried out in
five stages of L.P. heaters, one deareating heater and in two H.P. heaters
extraction 1, 2, 3, is taken from L.P. turbine. Extraction 4, 5, 6 and 7 are
taken from M.P. turbine. Extraction 8 is obtained from C.R.H. line first and
second stage of heating is done by two sets of twin low-pressure heaters
mounted directly in the L.P. casing of the turbine. Extraction 3, 4 and 5 are
connected to the deaereating heater placed above feed water storage tank 7th
and 8th extraction steam is fed to the vertical H.P. heaters respectively.

(C) REHEAT STEAM

Exit steam from the H.P. turbine is taken back to the reheater section of the
steam generating unit. Reheating is done in two stages both by flue gas and
by super heated steam. The steam to be reheated is first pass through the
triple-heated exchanger, where super heated steam is used as the heating
media. The steam is finally reheated in final reheaters (RHH3) RHH4 and
RHH5) suspended in the horizontal pass of the furnace. Reheat steam at a
normal pressure of 36.4 kg/cm2 at a temperature of 540°C respectively is fed
to the M.P. cylinder by two hot reheat steam pipes through strainers and
combined stop and interceptor valves. In each of the cold reheat steam lines
from H.P. cylinder a non-return valve is operated by oil pressure is provided.
 5. Turbine Accessories and Auxiliaries

I. Surface condenser.
II. Steam jet air ejector
III. LP and HP heaters.
IV. Chimney steam condenser.
V. Gland steam condenser.
VI. Oil purifier or centrifuge.
VII. Clean oil pump with clean oil tank
VIII. Dirty oil pump with clean oil tank.
IX. Auxiliary oil pump with auxiliary oil tank
X. Starting oil pump.
XI. Emergency oil pump.

(I) SURFACE CONDENSER

Two surface condensers are used for condensing the steam which has
worked in the turbine. The coolant for condensing the steam is circulating
water which is inside the condenser brass tubes and steam is outside.

Technical data of Condenser

• Cooling Area 3300 msq.

• Number of brass tubes 6000
• Circulating water required 7500 tonnes/hr.
• Vacuum in the condenser 0.90 kg/cm sq.
(II) STEAM JET AIR EJECTOR

Starting ejector is used for quick evacuation of the turbo set during starting
whereas main steam jet air ejector is used to maintain Vacuum in the
condenser. It works on the principle of ‘VENTURI’ with steam working
media to eject air from the condenser.

(III) LP AND HP HEATERS

In regenerative system there is a steam of 5 LP heaters, one Deaereator, 2

HP heaters. All LP and HP heaters are of surface type i.e. condensate or feed
water is inside the heater tubes in the heater shells. L.P. heaters are of single
flow whereas HP heaters are of double flow type. Deaereator is contact type
heater in which steam and condensate come in direct contact.

(IV, V) CHIMNEY STEAM AND GLAND STEAM CODENSER: - There

are additional two heating stages provided in the regeneration system of the
turbine for heating the condense flowing through it steam leaks off from the
turbine glands is used for heating the condensate in these heaters.

(VI, VII, VIII, IX, X) VARIOUS OIL PUMPS

Centrifuge is an oil purifier used to remove moisture and other impurities

from the turbine oil. Maximum allowable moisture content in the turbine oil
is 0.2%. In case the oil level of the main oil tank is to be made up then either
oil can transferred from clean oil tank to main oil tank with centrifuge or
from dirty oil tank to main oil tank with centrifuge.
(XI) STARTING OIL PUMPS AND EMERGENCY OIL PUMPS

Starting oil pumps supply the necessary turbine oil during starting of the
turbine and upto turbine speed of 2930 rpm till the main oil pump mounted
on the turbine rotor at the HP extension takes manually in order to provide
lubrication oil for the turbo set. Emergency oil pumps are meant to start on
auto, when turbine trips and lubrication oil pressure falls in order to provide
lubrication to the turbine and generator bearings.

MAIN TECHNICAL DATA ABOUT TURBINE

a) The Basic Parameters

• Rated output measured at terminal of the generator.
110,000KW
• Economical output. 95,000KW
• Rated speed 3,000 RPM
• Rated temp. Of steam just before the stop valve. 535°C
• Max temp. Of steam before the stop valve 545°C
• Rated pressure of steam before the MP casing 31.63 ata
• Max. Pressure of steam before the MP casing 35 ata
• Rated temp. Of steam before the MP casing 535°C
• Max. Temp. of steam before the MP casing 545°C

(a) System of turbine:

Governing valves 2 interceptor valves
HP cylinder 2 Row Curtis wheel +8 moving
wheels.

Wt. of HP rotor is approx. 5,5000kg.

MP cylinder 12 moving wheels.

Wt. Of MP rotor is approx. 11,000kg

LP cylinder 4 Moving wheels of double flow

design.

Wt. of MP rotor is approx. 24,000.

Direction of the turbine rotation is to the right when looking at the turbine
from the front bearing pedestal.

RELAY SECTION

Protective relay is a device that detects the fault and initiates the operation of
the circuit breaker to isolate the defective section from the rest of the system.

We have seen that whenever fault occurs on the power system, the relay
detects the fault and closes the trip coil circuit. This results in the opening of
circuit breaker, which disconnects the faulty section. Thus a relay ensures
the safety of the circuit equipments from damage which may be causes by
the faulty current.

ESSENTIAL ELEMENTS OF A RELAY

All the relays have the following three essential fundamental elements as
shown in block diagram see fig.

(a) Sensing element: - Sensing or measuring element is the element which

responds to the change in magnitude or phase of the actuating quantity e.g.
current in the over current relay.
(b) Comparing element: - It is the element which compares the action of
the actuation quantity of the relay with pre-designed relay setting. The relays
only pick up if the actuating quantity is more than the relay setting.

(c) Control Element: - When a relay picks up it accomplishes a sudden

change in the controlled quantity such as closing of trip coil circuit.

1. TYPES OF RELAYS

There are many kinds of relays applied in the power system. The relays can
be designed and constructed. To, operate in response to one or more
electrical quantities such as voltage, current, phase angle etc. The relays are
classified in different ways.

According to construction and principle of operation

(i) Thermal relays: - The heating effect of electric current is used for the
operation of these relays.

(ii) Electromagnetic attraction relays: - The operation of these relays

depends upon the movement of an armature under the influence of attractive
forces due to the magnetic field set up by current flowing through the relay
coil.

(iii) Induction Relays: - Electromagnetic induction phenomenon is used

for the operation of these relays by induction, eddy currents are induced in
the aluminum disc, free to rotate, which exerts torque on it.

2. ACCORDING TO APPLICATION

(i) Over current, over voltage or over power relays:-These relays operate
when the current, voltage or power rises beyond a specific value.
(ii) Directional or reverse current relays: - These relays operate when the
applied current assumes a specified phase displacement with respect to the
applied voltage and the relay is compensated for fall in voltage.

(iii) Under current, under voltage or under power relays: - These relays
operated when the current, voltage or power falls below a specific value.

(IV) Directional or reverse power relays: - These relays operate when the
applied voltage and current assumes a specified phase. Displacement and no
compensation is allowed for fall in voltage.

(V) Distance relays: - The operation of these relays depends upon the ratio
of the voltage to the current.

(Vi) Differential relays: - The operation of these relays takes place at some
specific phase difference or magnitude difference between two or more
electrical quantities.

3. According to the time of operation:-

(i) Instantaneous relays:-In these relays, complete operation takes place

instantaneously i.e., the operation is complete in a negligibly small interval
of time from the incidence of the actuating quantity.

(ii) Definite time lag Relays: - In these relays operation takes place after
definite time lag which is independent of the magnitude of actuating
quantity.

(iii) Inverse time lag Relays:–In these relays the time of operation is
inversely proportional to the magnitude of actuating quantity.
Inverse Definite Minimum Time Lag Relays: - In these relays, the time of
operation is approximately inversely proportional to the actuating quantity,
but is never less than a definite minimum time for which relay is set.

THERMAL RELAYS

A relay in which heating effect of electric current is used for its operation is
known as thermal relays. These relays may be actuated by a.c. or d.c.

CONSTRUCTION

The schematic diagram of an indirectly heated general purpose thermal relay

is shown in fig. It has a bimetallic strip which is heated by heating element
which gets supply from a current transformer. An insulated contact arm
carrying a moving contact is pivoted and is held by a spring. The other
contact of trip circuit is a fixed contact. The spring tension can be varied by
changing the position of contact arm with the help of sector plate.
WORKING
Under normal conditions, the current flowing through the heating element is
proportional to the normal full load current of the circuit. The heat produced
by the heating element, under this condition is not sufficient to bend the
bimetallic strip. However, when fault occurs current flowing through the
heating element increases which produces heat sufficient to bend the
bimetallic strip. This releases the contact arm and because of the spring
tension the relays contacts are closed which closes the trip coil circuit or the
alarm circuit once the alarm circuit or the trip coil circuit is closed; it
operates the alarm circuit or the circuit breaker to open the circuit
respectively.

These over current tripping relays are use mostly for motor controls. The
heating elements of such relays are designed to with stand short time
overload up to 7 times the normal full load.

ELECTROMAGNETIC ATTRACTION RELAYS

Electromagnetic attraction type relays are operated by virtue of an armature

being attracted towards the poles of an electromagnet. These relays may be
actuated by D.C. or A.C. quantities.

Construction

The schematic diagram of an electromagnetic attraction type relay is shown

in fig. It consists of a magnet which carries a relay coil having number of
tapings. The armature is held by the spring attached it. The armature has
spring loaded moving contact which bridges the trip coil circuit.
Working
Under normal conditions, the current flowing through the relay coil is such
that spring tension is more than the attractive force of the electromagnet.
Therefore armature is held in the open position. However when fault occurs,
current flowing through the relay coil increases. This increases the attractive
force of the electromagnet. At the instant when attractive force of
electromagnet is more than the spring tension, the armature is tilted down
wards and moving contact bridges the fixed contacts. This closes the trip
coil circuit.

The current setting can be adjusted by changing the number of turn of relay
coil. The larger numbers of turns are introduced in the operating coil, the
smaller is the value of actuating current. The time setting can adjust by
changing the tension of spring by a screw. Terminal AC act as normally can
also be used for the operation of another circuit.
INDUCTION RELAYS

The basic principle of operation of these relays is electromagnetic induction.

These relays are only actuated by a.c. An induction relay essentially consists
of a pivoted aluminum disc place in between two alternating fields of the
same frequency but displaced from each other by some angle. A torque is
produced in the disc by the interaction of two fields. Such relays may be
over current reverse power or directional over current relays as discussed in
the coming articles.

INDUCTION TYPE OVER CURENT RELAY

Construction
An induction type over current relay is shown in fig. 5 (a) it consists of an
aluminum disc which is free to rotate to be placed in between the two
electromagnets. The upper magnet has three limbs whereas lower magnet
has two. The tapped winding is wound on the central limbs of the upper
magnet. This winding is connected to the CT of the line to be protected. The
tapings one connected to a plug setting bridge as shown in fig.5 (a) by
changing the position of plug by which the number of active turns of the
primary winding can be varried, thereby the desired current setting is
obtained. The secondary is a closed winding and wound on the central limb
of the upper magnet and both the limbs of the lower magnet. The winding is
energized by the primary winding.

The controlling torque is provided by connected a spiral spring on the

spindle of the disc. The spindle of the disc also carries a moving contact,
when the disc rotated through a preset angle, the moving contact bridges the
two fixed contact of the trip coil circuit as shown in fig.5 (b). The preset
angle can be adjusted to any value between O° and 360°, by adjusting the
angle, the travel of the moving contact can be adjusted and the relay can be
set for any desired time setting.

Working
When current flows through the primary winding, an e.m.f. is induced in the
secondary winding by induction. Since secondary is closed, a current flows
through it. The fluxes are produced by the currents flows through primary
and secondary winding. These fluxes are separated in phase and space and
produces a driving torque on the disc. This torque is opposed by the
restraining torque provided by the spring. Under normal conditions, the
restraining torque is more than the driving torque, therefore, the disc
remains stationary.

However when a fault occurs, the current flowing through the primary
exceeds the preset value. The driving torque becomes more than the
restraining torque consequently the disc rotates and moving contact bridges
the fixed contacts when the disc rotates through a pre-set angle.

Specification of over current relay

S.No. M292523
Model NO. CDG 31EG 1212 A5
Type Auxiliary voltage 220V d.c.
Manufacturer Jyoti Ltd. Baroda.
 CONCLUSION

Spending Our six months of training in Guru Nanak Dev Thermal Plant, Bathinda, We

concluded that this is a very excellent industry of its own type. They have achieved

milestones in the field of power generation. They guide well to every person in the

industry i.e. trainees or any worker. We had an opportunity to work in various sections

namely switch gear, Boiler section, Turbine section, EM-2 CELL etc. while attending

various equipments and machines. We had got an endeverous knowledge about the

handling of coal, various processes involved like unloading, belting, crushing and firing

of coal. The other machines related to my field that We got familiar with boiler, turbine,

compressors, condenser etc. We found that there existed a big gap between the working

in an institute workshop and that in the industry. Above all the knowledge about the

production of electricity from steam helped me a lot to discover and sort out my problems

in my mind related to the steam turbine, their manufacture, their capacity, their angle of

blades and their manufacturing. The training that We had undergone in this industry will

definitely help me to apply theoretical knowledge to the practical situation with

confidence.
 BIBLIOGRAPHY

1. A Textbook of electrical technology (A.C & D.C Machines) – B.L.THERAJA, A.K.THERAJA

2. A course in electrical power: - J.B.GUPTA

3. A course in electrical & electronic measurement and instrumentation: - A.K.SAWHNEY

4. A course in electrical power: - M.L.SONI, P.V.GUPTA

5. A textbook of power plant engineering: - Er. R.K.RAJPUT

6. www.wikipedia.com

7. www.sensorland.com

8. Manual of GURU NANAK DEV THERMAL PLANT, BATHINDA.

ACKNOWLEDGEMENT
 I am really grateful and convey my deep sense of gratitude and
appreciation to the officers/officials at G.N.D.T.P. BATHINDA for their
valuable guidance and unstinted co-operation throughout this summer
training. We would like to thank Er. T.N BANSAL ADD. S.E at
G.N.D.T.P BATHINDA for providing us an opportunity to work under his
thorough guidance and critical intervention during our training . Most of all
we wish to thank Er. Ravinder Pal Singh (T.T. Cell) for their valuable
help in providing relevant data and all the logistic facilities which have
contributed immensely towards the smooth progress and preparation of this
report.

Sukhjinder Singh
008545335630
Mechanical Engineering

TRAINING REPORT
OF
45 DAYS INDUSTRIAL TRAINING REPORT
 AT

THERMAL POWER PLANT

BATHINDA

SUBMITTED BY
SUKHJINDER SINGH
008545335630

Mechanical Engineering
G.G.S.C.E.T. TALWANDI SABO
SUBMITTED TO
TRAINING CELL

G.N.D.T.P, BATHINDA