2

REPORT ON SIX WEEKS INDUSTRIAL TRAINING

SUBMITTED FOR THE PARTIAL FULFILLMENT OF THE DEGREE
OF
BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)

SUBMITTED BY :SUBMITTED TO:SAHIL KUMAR KAMRA

ROLL NO.1250736
B.TECH (M.E)

MR.MUNISH KUMAR &

GURNAM SINGH
(Training Incharge)
(Mech. Dept.)

ACKNOWLEDGMEN
T ACKNOWLEDGMEN
T

We take this opportunity to express our gratitude to our project guide, training
manager and esteemed personality MR.R.K.SINGLA under whose expert guidance we
completed our project successfully. We are grateful for his encouragement, valuable
suggestions and guidance. He provided us with valuable tips and solutions to our
repeatedly occurring problems. Our sincere, effective and deep gratitude is due to him for
his excellent spirit, effective guidance, which gave us the confidence to complete the
work of training and project work.
We are also thankful to the Technical Training Cell (T.T.C) at G.N.D.T.P.
Bathinda. MR.ANIL SHARMA who introduced us to the problem and provided us with
valuable data, without which our project could not come to an existence. They were
instrumental in providing us with various lines to think on.
We are also thankful to our friends and class mates for their constructive
criticism. They helped us a lot in completing our project successfully.

INDEX
INDEX

SERIAL
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13

CONTENT
INTRODUCTION
BRIEF HISRORY OF PLANT
CONTRIBUTION OF THE PLANT
HISTORY OF THE THERMAL POWER PRODUCTION
WORKING OF THE THERMAL PLANT
PLANT SALIENT FEATURES
BASICS OF THE THERMAL POWER PLANT
GENERAL DESCRIPTION
GENERAL ASPECTS OF BOILER
ID FAN
FD FAN
PA FAN
CONCLUSION

PAGE
NO.
5
6
7
8
10
13
15
21
25
31
34
37
40

INTRODUCTIO
INTRODUCTIO
N
N
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 BRIEF

BRIEF HISTORY
OF
OF
PLANT
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, January 1979 respectively. The power available from this plant gives spin to the
wheels of industry and agricultural pumping sets.

CONTRIBUTION
CONTRIBUTION
OF
OF
THE PLANT
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.

HISTORY OF
HISTORY OF
THERMAL
THERMAL
POWER PRODUCTION
POWER PRODUCTION

Although electric power generation in India on a commercial basis is almost a

century old, substantial power development efforts began only after independence. At the
launch of the First Five-Year plan in 1951, power generation was recognized as a major
input for the country's economic development and was accorded high priority. Power
sector outlays have been among the highest in successive Five-Year Plans ever since. The
first two Plans focused on hydro power (as component of multi-purpose projects).
Subsequent plans emphasized on rapid installations of thermal power stations.
As a result of Plan efforts, India's installed power generation capacity grew to
16,664 MW in 1974. However, assessment of the planned growth since 1951 indicated
that with the uneven distribution of resources, power development with only States as
spatial units, would result in large inter-state imbalances. This, and the need for quicker
and greater capacity addition, led the Government of India to assume a leading role in
large scale power generation as a matter of policy and, through an amendment of the
Electricity (Supply) Act, National Thermal Power Corporation Ltd. (NTPC) and National
Hydroelectric Power Corporation Ltd. (NHPC) were set up in the central sector to
supplement the efforts of the States.
Consequently, total installed capacity of power utilities has increased from 1,362
MW in 1947 to 104918 MW in March, 2002. Electricity generation, which was only
about 4.1 billion units in 1947, has risen to 515 billion units in 2001-02.

PRESENT SCENARIO :As on March 2003, the total installed capacity of utilities stood at 104,918 MW.
Most of this installed capacity is under government control. The state governments
control nearly 60% of the power generating capacity. Currently, the central government
owns about 30% of the power generating capacity in the country, the majority of which is
in the thermal sector. Of the total installed thermal capacity of 25366.50 MW in Central
sector, NTPC's share is 20092 MW (76.61%).

Source

Central

State

Private

Total

share

of total
Coal

21417.51

36302

4414.38

62130.89

59.22

Gas

4419.00

2661.70

4082.40

11163.10

10.64

Diesel

582.89

551.94

1134.80

1.08

Total Thermal

25836.51

39546.59

9045.72

74428.82

70.94

Hydro

3049.00

22636.0

576.20

26261.22

25.03

Nuclear

2720.00

2720.00

2.59

Wind

62.86

1444.60

1507.46

1.44

Total

31605.51

62245.47

11066.52

104917.5

100.00

10

WORKING OF
WORKING OF
THERMAL
THERMAL
PLANT
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.

11

12
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.

13

PLANT SALIENT
PLANT SALIENT
FEATURES
FEATURES
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/cm

Reheater outlet pressure

33.8 kg/cm

Final superheater/reheater temperature

540C

Feed water temperature

240C

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/cm

Rated temperature

535C

Condenser vacuum

0.9 kg/cm

14

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

10C

Height

120/122 metres
COAL PULVERISING MILLS:-

Numbers

three per unit

Type

drum-ball

Rated output

27 T/hr.

BASICS OF THERMAL
BASICS OF THERMAL

15

POWER PLANT
POWER PLANT
Thermodynamics is the main subject of Thermal Engineering. It deals with the behavior
of gases and vapors, when they are subjected to varying temperatures and pressure. In a
thermal power plant, heat energy of the steam is converted to mechanical energy of the
turbine, which is further converted to electrical energy with the help of a generator. The
simple circuit of thermal plant can be drawn as below:\

Some of the definitions dealing with the thermodynamics are as below:GAS:- A gas is the name given to the state of any substance of which the evaporation
from the liquid state is complete. For example Hydrogen, Oxygen and air etc.
VAPOUR:-A vapor may be defined as a partially evaporated liquid and consists of the
pure gas state along with particles of liquid in suspension. It does not behave in the same
way as the gas, as the substance is further liable to the evaporation. When a vapor
becomes completely evaporated, it is said to be dry and any further heating of a dry vapor
is termed as super heating. Once a vapor is superheated it is approx. behaves as a gas.
HEATING OF A GAS:- A gas may be heated while either its volume is kept constant or
its pressure is kept constant, when the volume is kept constant, the temperature, pressure
will increase as the heat is supplied to a gas. But there will be no work done by the gas as
there is no change in volume. But when the gas is heated at constant pressure then the
volume increases and some work is done by the gas in expanding.
Work = pressure x change in volume

16

INTERNAL ENERGY OF GAS:- The internal energy of a gas is the heat

energy stored in the gas. It is quantity of heat. If the quantity of steam is
applied to a gas, the temperature of gas may increase or its volume may
increase thus doing external work or it may do both, the result will depend
upon certain set of conditions under which heat is supplied to gas. If this
heating is accompanied by a rise of temperature, the gas will increase its
internal energy. This means that some of the heat supplied has been stored in
gas in the form of heat energy. Thus producing the rise of temperature the
gas will have increased its internal energy. This means that some of the heat
supplied has been stored in the form of heat energy, remaining is given out
by gas as the form of external work as gas increased its volume. The
increase in heat energy stored in the gas due to rise of temperature is called
the increase of internal energy.
LAW OF CONSERVATION OF ENERGY:Total heat supplied to a gas must be equal to the
increase of internal energy plus any external work done by
the gas in expanding.
H = total heat supplied to gas
E = increase in internal energy
W = external work done by gas
Then H = W + E
ISOTHERMAL EXPANSION:- Heat can be supplied to a gas keeping its temperature
constant. In this case the gas will expand doing external work equal to the amount of heat
supplied. This type of expansion is called Isothermal Expansion.

17
ADIABATIC EXPANSION:- When a gas expands, doing external work in such a
manner that no heat is supplied or rejected during the expansion. Such an expansion is
called adiabatic expansion.
ENTHALPY :-The total heat of substance is known as its enthalpy.
BASIC TYPE OF STEAM POWER PLANT :- The conversion of heat energy of
organic or nuclear fuel into mechanical energy with the aid of steam is carried out in
steam power plant. A diagrammatic view of the simplest steam power plant is shown on
next page :-

The initial state of the working body is assumed to be water, which at a certain
temperature is compressed by the pump BFP and is fed into boiler B through
economizer E. In the Boiler water is heated at constant pressure process (4-5),
to its Boiling point. When the vaporization takes place in the same boiler
process (5-6), since dry saturated steam is rarely used in power plants, it is
superheated to the required temperature in superheated state.
The steam which is superheated through a pipe flows to steam turbine T.
Where it undergoes adiabatic expansion producing some external work (process 1-2). To
have the steam produce more work, its pressure at the turbine outlet must be as low as
possible. For this purpose steam from turbine is exhausted to a special apparatus
condenser C, in which the pressure of below atmosphere (vacuum) is created. In the
condenser latent heat of vaporization is removed from the steam with the aid of cooling
water and the steam condenses into liquid (the process of condensation 2-3) at a constant
pressure and temperature. Then this cycle is reheated. The basic cycle of the steam power
plant considered above is called the Rankine cycle.

18
R = H1 H2
H1 Hw
where
R = Rankine efficiency
H1 = enthalpy of steam at turbine inlet
H2 = enthalpy of steam at turbine outlet
Hw = enthalpy of condensate

METHODS OF INCREASING EFFICIENCY:Raising the initial steam pressure:- By increasing the initial pressure at turbine inlet,
the enthalpy drop (H1 H2) can be increased. Thereby increase in thermal efficiency of
Rankine cycle. However it must be mentioned that an increase in the initial steam
pressure results in increase in the wetness of the steam at the end of expansion. The drops
of liquid of steam can appearing in the steam at the last stage of the turbine cause erosion
of blades and reduce overall efficiency of turbine.
In order to avoid this increase in steam wetness above the tolerated value, an
increased temperature of the superheated steam as well as reheating may be employed.

19

REHEATING :-

Reheating:-

Reheating consists of subjecting steam to repeated super

heating, after it
has expanded in the first cylinder of the turbine, at originally constant pressure in the
reheaters to original temperature, then the steam is directed into the second cylinder of
the turbine T2, where the steam expands and goes to the condenser. Reheating increases
dryness fraction of steam. It also results in the thermal efficiency of the cycle.

20

Raising the temperature of superheating:- By raising the temperature of superheated

steam at constant pressure, the heat drop (H 1-H2) increases. As a result efficiency
increases. Increasing the temperature of superheated steam also increases the dryness
factor. In modern steam power plants the temperature of superheating is limited. By the
heat resistant properties of the metal used.
Increasing the vacuum at condenser or reducing pressure at final:- A reduction in the
final pressure increases the heat drop (H1-H2) which results in the increase in the thermal
efficiency of the cycle.
Regenerative feed heat cycle:- In this system, the steam is fed from the turbine at
certain points during its expansion and is utilized for preheating the feed water supplied
to the boiler. At certain sections of turbine a small quantity of wet steam is drawn from
the turbine. This steam is circulated around the feed water pipe leading from the hot well
to boiler. The relatively cold water causes this steam to condensate. The heat thus lost by
the steam being is transferred to the feed water; the condensed steam then drains into the
hot well.
The net effect of this process is to supply the boiler with hotter water while a small
amount of work is lost by the turbine. There is a slight increase in efficiency due to
this process, but there efficiency depends upon following factors: Steam pressure
Degree of superheat in steam
Reheat/nonreheat
Vacuum in condenser
Regenerative/ non regenerative cycle

21

GENERAL
GENERAL
DESCRIPTION
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:a) 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

Delivery capacity

445 t/hr.

Feed water temperature

158C

Speed

4500 rpm

Pressure at suction

8.30 kg/cm

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.

22
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.

23

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 10C. Cooling towers are massive ferro-concrete

24
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 1500C. 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.

25

GENERAL ASPECTS
GENERAL ASPECTS
OF BOILER
OF BOILER

GENERAL DESCRIPTION
The steam generator is of radiant, reheat, natural circulation, single drum, dry
bottom and semi-out door type unit, designed for firing coal as principle fuel and the
HFO oil firing capacity is equivalent to 22.5% boiler MCR, 4 LDO burners are capable
for 7.5% boiler MCR heat input. Layout arrangement is of conventional type i.e. with the
mills in front of the boiler. The complete furnace section is of fusion welded wall type,
arranged as a gas and pressure tight envelop. The extended sidewall section (where reheaters are located) is covered with water-cooled fin welded walls.
The super heater steam system has mainly three sections.

26
1. LTSH section (arranged in the back of the unit)
2. The radiant platen super heater (arranged at the outlet section of the furnace)
3. The final super heater (arranged after the re-heater).
Two numbers super heaters and de-super heaters are provided in between the LTSH
section and platen super heater (in the connection links) for controlling super heated
steam temperature over wide load range. The complete back pass of boiler (up to the
economizer) has been covered with steam super heater wall sections.
The complete re-heater has been arranged as one section and located in the
horizontal pass of the boiler in between the radiant platen super heater and final super
heater. Two numbers re-heater, de-super heaters are provided for emergency control of
the final reheat steam temperature.
The maximum flue 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 hand holes plate
arrangement. All the headers are located out side the gas path, except for the economizer
inlet header, intermediate headers and LTSH inlet header are located in the low gas
temperature section. The complete pressure parts are suspended from the boiler structural
steam roof sections and arranged for free expansion downward.
BOILER EFFICIENCY
Boiler efficiency is defined as the heat added to the working fluid expressed as a
percentage of heat in fuel being burnt. The theoretical limit to boiler efficiency is 100%
unlike in case of turbo generator, whose efficiency is limited by cycle efficiency. Boiler
heat only because it would be extremely difficult and not a paying proposition to recover
it all. Thus maximum boiler efficiency is thought in terms of an optimum efficiency,
which depends on fuel being burnt and the fact that waste products of combustion take
away heat with them.
Boiler efficiency depends solely on the boilers ability to burn the fuel and transfer the
resulting heat to water and steam. The pressure and steam, although profoundly altering
cycle efficiency and turbine efficiency, have no material effect on boiler efficiency.

27

The boiler efficiency will depend to great extent on the skill of their designing but there is
no fundamental reason for any difference between a high pressure boiler and a low
pressure boiler or between a reheat and non-reheat. Generally speaking a large boiler
would be expected to be more efficient than small boiler, and as increase in pressure and
temperature have developed; it has been accompanied by an increase in size. So there
might be tendency to think that higher efficiency of most modern boiler is due to advance
steam cycle condition where as it is infect attributable to increase in physical size and
improvement in the art of boiler making in general fuel burning in particular.
A boiler, however must be able to meet the following design requirements : Be able to produce steam at required temperature and pressure over an appreciable
range load take in feed at a temperature which varies with turbine load.

Be capable of following changes in demand for steam without excessive pressure

swing.
Be reliable with high availability

28
LOW TEMPERATURE SUPER HEATER
The LTSH section is of continuous loops, plain tubular, drainable, horizontal, in
line spaced type, with steam flow upwards and gas flow downwards arrangement. This
section is in two blocks and located above the economizer section, in the back pass of the
unit. This convective spaced bearing surface has 120 assemblies, 4 elements per
assemblies. The out let section of LTSH alone is arranged vertically.
RADIANT PLATEN SUPER HEATER
The radiant platen super heater is of the continuous loop, plain, tubular, nondrainable, vertical inline tangent tube type, arrangement for parallel flow. The platen
super heater section assemblies are widely spaced, and located in the radiant zone at the
furnace outlet section. The radiant platen heating surface has 29 assemblies, 7 elements
per assembly.
FINAL (FINISH PENDENT) SUPER HEATER (FSH)
Final pendent super heater (FSH) section, is of spaced type continuous loop, plain
tubular, non-drainable, vertical in line spaced type, arranged for parallel flow. This FSH
is located in the horizontal pass, after re-heater section. The convective final super heater
has 89 assemblies-2 elements per assembly.
RE-HEATER SYSTEM
The re-heater section is single stage, spaced type, continuous loop and plain
tubular, non-drainable, vertical inline spaced type, and arranged for parallel flow. The reheater front pendent and rear pendent section is located in the horizontal pass, in between
the radiant platen super heater and final super heater section. This convective re-heater
section has 59 assemblies-6 elements per assembly. The approximately total convective
heating surface is 3100 m. The entire re-heater section is suspended from the roof
structural steel sections.

29
SUPER HEATER, DE-SUPER HEATER
For controlling the final super heat steam temperature at the rated valve, two
numbers of spray type de-super heaters are located in the steam connecting links between
the LTSH outlet header and platen SH inlet header, this inter stage de-super heater is of
welded type. Spray tubes and liners are provided.
For emergency control of re-heater outlet temperature, two numbers of spray type
de-super heater provided. These are located in the cold re-heat piping and used during
any abnormal emergency conditions for steam temperature control. The de-super heaters
are of welded type spray nozzles are provided.
ECONOMIZER SYSTEM
The economizer, a single block unit, is of continuous loop plain tubular, drainable,
horizontal, in line arrangement with water flow upward and gas flow downwards. The
economizer tubes are suspended from economizer intermediate header, using ladder type
supports. The heating surface is 4550 m. An economizer re-circulative system is
provided, connecting the down comer and economizer inlet pipe to ensure required flow
through economizer tubes during starting conditions of the unit.
STEAM DRUM
The steam drum is of fusion-welded construction, fabricated from carbon steel
plates. At each end of the drum, a manhole is provided to open inwards. The drum is
located on the upper front of the unit, the ID of steam drum are welded type. The drum is
equipped with primary turbo separators, secondary corrugated scrubbers and screen
dryers, to the limit the solids carry over in the steam living in the drum. All turbo
separators (along with scrubbers) and the screen dryers are of removable types. The drum
is suspended from boiler roof structures.
DOWN COMER PIPES
There are six down comer pipes are provided, connecting the steam drum and
water wall lower ring heater.
WATER WALL SYSTEM

30
The water wall system comprises of front wall, rear wall, side walls all of fusionwelded construction.
RISER PIPES
From the outlet headers of the water wall system, the steam water mixture is taken
to the steam drum through 118 numbers pipes rolled up-risers.
WATER WALL/FURNACE DESIGN PRESSURS
The complete furnace wall, and the other steam cooled walls (in the second pass),
are strengthen by providing buck stays and tie bars system to with stand pressure/forces
SUPPORTS/SUSPENSION
The complete circulation system is suspended from boiler roof structure & is
arranged for free expansion downwards.
FURNACE
The furnace hopper outlet section is provided with an opening of approx.1100 mm
depth for full width of the furnace. On each sidewall, in the furnace hopper area, one
water-cooled access door (oval in shape) is provided. These openings are provided for
taking maintenance cradle parts/ scaffolding sections etc. inside the furnace during
maintenance of the furnace.
SPECIAL FITTING AND VALVES
Access doors, feed water valves, gauge glasses and safety valves etc. are included
under this heading. The access doors are installed at:
FEED REGULATION STATION
The location of this station is at AB elevation and feed water supply to the boiler
is regulating through this station. During initial period of starting the unit, feed is
regulated through 30% line because the requirement of water is small during this period.

31

INDUCED DRAFT FAN

FUNCTIONS:
1. To remove flue gases from the furnace and throw it in a atmosphere through
chimney.
2. To maintain ive pressure (draft) in the furnace i.e. 5 mm WC to 7 mm WC.
The type AN fan operates according to the impulse principle. The major
part of the energy transferred to the gas appears as the velocity energy after the impeller.
This velocity energy is converted into pressure energy by the diffuser. Usually, the AN
fans are driven at constant speed and the flow is controlled by changing the direction of
gas entering to impeller blades. For this purpose, adjustable guide vanes are used before
the impeller.
TECHNICAL SPECIFICATIONS: 1. Type

: AN 25e6
where
AN axial non-profiled bladed fan
25- Nominal tip dia of impeller in
decimeter
e6 type of diffuser

2. No of fans

:3

3. Medium Handled

: Flue gas

4. Location

: Ground

5. Orientation

: Inlet vertical
: Outlet horizontal

FAN DESIGN RATING

6. Capacity
7. Total head developed

: 230 m3/s
: 350 mm WC

8. Temperature of medium

: 1500 C

9. Specific weight medium

: 0.813 Kg/m3

32
10. Speed

: 980rpm

FAN RESERVE
11. Flow

: 35.7%

12. Pressure

: 38.3 %

FAN DRIVE COUPLING

13.Make

: BHEL

14.Type

: Flexible

DRIVE MOTOR
15.Make

: BHEL

16.Frame size

: AC 14256 H6 A8H

17.Type

: Square cage induction

18.Rating

: 1300KW

19.Speed

: 980rpm

20.Fan weight

: 21.7 tons

LUBRICATION
21.Fan

:Grease Servo Gem EP2

22.Motor

:FOLS Mobile DTE of IOC

23.Type of fan regulation

:Inlet guide vane

BEARINGS
24.Fan fixed bearing
25.Fan expansion bearing

: Anti friction 22328 C3

: Anti friction 22232 C3

STARTING PERMISSIVES: 1.Suction and discharge damper in closed position.

2.Central actuator or regulating vane in minimum position.
3.Central station on manual position.
4.Stack path available.
5.Lubricant oil system O.K. (from local fan panel ). For this condition to be O.K.
following is required: a) Fan bearing (DE and NDE) temperature normal 950 C.

33
b) Motor bearing (DE and NDE) temperature normal 750 C.
c) Lubricant oil pressure O.K. 1.5 Kg/cm2.
d) Control supply of fan panel should be on.
6.Local push button reset.
TRIPPINGS
Lubricant oil pressure 0.4 Kg/cm2 with a delay of approximate of 0.45
seconds.
Motor bearing temperature very high 850C.
Fan bearing temperature very high 1050 C.

PARAMETER BEING0MONITORED DURING RUNNIG OF FAN

UCB
Meter current
Vane position

LOCAL
1. Fan ( DE and NDE) bearing temperature
2. Motor bearing ( DE and NDE) temperature
3. Lubricant oil pressure
4. Lubricant oil temperature
5. Running of pump A or B.

34

FORCED DRAFT FAN

FUNCTION:
1.

To supply air at required pressure to furnace for proper combustion.

2. To control the quantity of air in the furnace.

In the axial reaction fans (Type A P), the major part of ( about
80%) energy transferred is converted into static pressure in the impeller itself. The rest of
the energy is converted into static pressure in the diffuser. These fans are generally driven
at constant pace. The flow is controlled by varying the angle of incidence of impeller
blades. It therefore becomes possible by this process to achieve high efficiencies even
during part load operation.
TECHNICAL SPECIFICATIONS:
Type
Where A.P.-1. Single stage axial

: A.P. I-18/11
profile bladed fan.

18- Nominal tip dia of impeller in decimeter

11- Nominal hub dia of impeller in

decimeter.

No of fans

: 2 per boiler and both running

Medium handled

: Air

Location

: Ground

Orientation

: inlet vertical outlet horizontal

FAN DESIGN RATING

Capacity

: 110m3/s

Total Head developed

: 520 mm WC

Temperature of medium

: 500C

Specific Weight medium

: 1.044 Kg/m3

Speed

: 1480rpm

FAN RESERVE
Flow

: 43%

Pressure

: 49%

35
FAN DRIVE COUPLING
Make

: Unique transmission

Type

: RIG/FLEX COUPLING

DRIVE MOTOR
Make

: BHEL

Frame Size

: MC 74224 H4 A8H

Type

: Square cage induction

Rating

: 750 KW

Speed

: 1480 rpm

Fan weight

: 8.4 tons

LUBRICATION
Fan
Type of fan regulation

: FLOS ISO VG 68
: Blade pitch control

BEARING
Fan fixed bearing

: 7230 BUA

Fan free bearing

: NU 230 C3

RECOMMENDED BEARING RADIAL CLEARANCES

Before mounting
: 0.115 mm to 0.150mm
After mounting

: 0.065 mm to 0.100mm

OPERATION OF FD FAN : 1. One FD fan should be running for starting one FD fan and two ID fans should be
running for starting second FD fan.
2. Discharge damper should be in closed condition.
3. Control station should be on Manual Mode.
4. Regulating vane or controlled actuator should be in minimum position.
5. Lubricant oil system O.K. from fan pane. This includes:
a. Control oil pressure after pumps should be adequate i.e. 8 Kg/cm2.

36
b. NDE/DE bearing temperature of fan normal 950 C.
c. NDE/DE bearing temperature of motor normal 750 C.
d. Control supply on.
6. Local push button reset.
TRIPPINGS: 1. Lubricant oil pressure low (less than 0.4Kg/cm2).
2. Motor bearing temperature very high 850C.
3. Fan bearing temperature very high 1050C.
4. ID fan trip condition one ID fan will trip one FD fan and both ID fans will trip
both FD fans.
Note:
Control vane of FD fan will not operate till control oil pressure is not adequate i.e.
it should be 8 kg/cm2.

37

PRIMARY AIR FAN

FUNCTION: -

P.A. fan is a part of F.D. fan system. It also supply

air in the furnace for combustion. Air supplied by P.A. fan and F.D.
fan combine together to make total air flow in the furnace.
Air supplied by P.A. fan is used to dry and transport the
pulverized coal from coal mill to furnace and is referred to as primary air.
In this type of fans, the medium handled enters the impeller axially and
after passing through the impeller leaves radially. A large part of the energy transferred to
the medium is converted into pressure energy. Constant speed motors generally drive
these fans. The output of the fan is usually controlled by inlet dampers or inlet guide
vanes or by varying the speed of the fan by suitable speed control device.
TECHNICAL SPECIFICATIONS:
No. of fans

Type

NDV 22 TIEF
Where
NDV Radial single
suction simply supported
22 nominal tip dia of
impeller in decimeter
TIEF Type of impeller.

Medium handled

: Air

Location

: Ground

Orientation

: Inlet 450 inclined, outlet

bottom horizontal

38
FAN DESIGN RATING
Capacity
Total head developed

: 70 m3/ sec
: 1220 mm WC

Temp of medium

: 500C

Specific weight of medium

: 1.044 Kg/m3

Speed

: 1480 rpm

FAN RESERVE
Flow

: 84.7%

Pressure

: 51.5%

FAN DRIVE COUPLING

Make

: VOITH

Type

: Hydraulic

DRIVE MOTOR
Male

: BHEL

Frame size

: M C 75288 H4 ATH

Type

: square cage induction

Rating

: 1259 KW

Speed

: 1480 rpm

Fan Weight

: 18.9 tons

LUBRICATION
Fan

: FLOS ISO VG 68

Motor

: Servo gem 3

BEARINGS
Fan fixed bearing

: SLEEVE BRG RT 70

Fan free bearing

: SLEEVE BRG RT 70

39
RECOMMENDED BEARING CLEARANCES
Axial gap (A)
Side clearance

: 0.380 to 0.760 mm

: 0.190 to 0.245mm

Oil clearance

: 0.180 to 0.290 mm

OPERATION OF A PA FAN
STARTING PERMISIVERS: Discharge damper should be in the closed condition.
1. Control station should be in the manual mode.
2. Control actuator should be in minimum position.
3. The one FD fan should ON for starting single PA fan.
4. Lubricate oil system O.K. This comprises: i. Lubricant oil system O.K. and pressure should be adequate 0.8 Kg/cm2.
ii. Motor bearing temperature is less than 750 C.
iii. Fan bearing temperature O.K. less than 750 C.
iv. Hydraulic coupling oil tank temperature O.K. less than 600 C.
5. Local push button reset.

40

CONCLUSION
CONCLUSION

Spending my six week of training in Guru Nanak Dev Thermal Plant, Bathinda, I
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. I had an opportunity to work in various sections
namely Boiler section, ID fan , FD fan, PA fan while attending various equipments and
machines. I 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 I got familiar with boiler, turbine, compressors,
condenser etc. I 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 I had undergone in this industry will definitely help
me to apply theoretical knowledge to the practical situation with confidence.