Thermal Power Plant
Thermal Power Plant
Thermal Power Plant
LIMITED
GENCO-III
THERMAL POWER STATION MUZAFFARGARH
INTERNSHIP REPORT
1st August 2019 – 1st September 2019
Submitted By:
Muhammad Qasim
CIIT/FA17-BME-076/SWL
Submitted To:
Internship Supervisor
Preface
Theoretical knowledge is not so important without a combination of exercise. It is part of their
academic curriculum to complete internships of BS students (mechanical engineering) in various
technical subjects to give students the opportunity to acquire practical and procedural
knowledge. As a sub-filament of Bs (Mechanical Engineering), the author of this report was also
given the task of drafting the semester report. The topic was "(GENCO-III) Northern Power
Generation Company Limited". Adapting to such a large organization was not an easy task, but
by the grace of Allah it helps my internship in an advantageous way and I learned a lot about the
generational enterprise in general. This report is a complete summary of my rigorous studies that
I conducted over a one-month period at the generation company. I studied and monitored the
operation of the company and did everything possible to keep pace with all dimensions of the
production company. It was a great experience to work there and to learn the difficulties. I thank
everyone who helped me in one way or another, and guided me in presenting ways to prepare
and compile this report.
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Acknowledgment
We thank ALMIGHTY ALLAH, who gave me the strength to think, plan and act in accordance
with the principles that allow us to do my internship.
It is a literary tradition to recognize the contribution and help of different people and
organizations to complete an internship, but in fact some words cannot express our gratitude for
the various helping hands. It is very difficult to appreciate each one for their contribution,
without these people it would be difficult for us to complete this internship successfully.
In addition, we would like to thank our internship director "Ing. Muhammad Shahid AME
Thermal Power Plant Muzaffargarh", who took the time to listen to us, guide us and continue to
find us the right way and make it possible, despite the extraordinary attention to their tasks.
Working as an industrial coach in his esteemed organization and extending it during training.
Internship Supervisor
Eng. Muhammad Shahid (AME)
Thermal Power Station Muzaffargarh
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DEDICATION
At the beginning, he dedicated this work to Almighty Allah, without his compassion and
compassion I could not do this work. The almighty ALLAH gave me strength and confidence to
complete my internship, and also the HOLY PROPHET HAZARAT MUHAMMAD (peace be
upon him), who is a light For humanity I dedicate this work also to my adorable parents with
deep gratitude, their love and Prayers have always been a source of strength for me.
I would also like to mention my father and mother, who have always been a source of inspiration
to me, assisting me in every one of my decisions, and allowing me to make mistakes, as mistakes
made the man I am today.
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EXECUTIVE SUMMARY
In accordance with the requirements for an internship, I spent a month at GENCO from 01-08-
2019 to 01-09-2019. That was a lot of study time for me. This internship report is about the
Muzaffargarh thermal power plant, also called GENCO-III. In GENCO-III there are a total of 6
units in which Phase I consists of 210 MW each and Phase II consists of 2 units of 210 MW each
and a separate unit, Unit 320, with a capacity of 320 MW . Then a total of 1370 MW of
GENCO-III. The installed generation is an oven oil production consisting of a steam turbine and
a water pipe boiler. Different types of generator and transformer protection are discussed in this
Repot. The circuit breakers and their types and relays will be briefly explained, as well as the
role of the instrument transformer. The important maneuvering yard is detailed. Later, all kinds
of engines come to light.
In this report, I gave an introductory story of GENCO-III. I have spent many days in various
sections of Division No. 4, including boiler, turbine, pumping and chemical stations. In this
report I describe the work and functions of these departments. In this report, I did a SWOT
analysis. There are also some recommendations at the end.
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Table of Contents
4. Capacity ......................................................................................................12
4.1 Phase-1……………………………………………………………………….12
4.2 Phase-2………………………………………………………………………..12
4.3 Some Key Facts………………………………………………………………12
Week-1
5. Boiler ………………………………………………………………………13
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Week-2
6. Cooling Tower………………………………………………………………18
6.1 Working…………………………………………………………………………..18
6.2 Cross Flow Cooling……………………………………………………………….19
6.3 Circulating Water Pump…………………………………………………………..19
8. Valve………………………………………………………………………...22
Week-3
9. Steam Turbine…………………………………………………………………24
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11.1 Rotor……………………………………………………………………………..25
11.2 Steam Chest and Casing…………………………………………………………25
11.3 Casing Sealing Glands…………………………………………………………..25
11.4 Over-speed Trip System…………………………………………………………25
12.1 HP Turbine…………………………………………………………………..26
12.2 IP Turbine…………………………………………………………………….26
12.3 LP Turbine…………………………………………………………………..26
18. Condenser…………………………………………………………………28
20. LP Heaters………………………………………………………………..29
21. HP Heaters………………………………….…………………………….29
Week-4
22. Couplings………………………………………………………………...30
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24. Bearing…………………………………………………………………..34
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1. Plant Layout
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3. Mission statement:
Our mission is to provide our customers with the certainty of energy, with first class quality and
commitment to satisfaction, while striving for excellence.
3.1 Background:
Northern Power Generation Company Limited owns and operates thermal power plants in
Muzaffargarh, Multan and Faisalabad. The installed capacity of the generation capacity is 1921
MW, which has decreased over the years to a reliable capacity of 1169 MW, which limits the
company's operational and financial performance due to internal and external factors. The
company has achieved a negative result, which has jeopardized sustainability.
The Government of Pakistan has set itself the objective of addressing the problems of the
country's energy sector through the implementation of the energy sector reform program. Under
the program, GENCOs, including NPGCLs, had to develop and implement business plans to
respond effectively to limitations and barriers to satisfactory performance.
3.2 Introduction:
This thermal power plant is located in the Muzaffargarh district of the Multan division. In 1985,
Ghulam Ishaq Khan concluded an agreement with Russia on the construction of the power plant.
This project was originally documented for Multan. But for certain reasons such as farmland,
costs, etc., this project was relocated to Muzaffargarh called Multan-II. Initially, three units
called Phas-1 were founded in Muzaffargarh. These units are also called Russian units. These
units work with oil and gas. Every 210MW of power. China is configuring its units to meet
electricity needs. These units also have 210 MW. China also founded a unit called # 4 witches
with a capacity of 320 MW. Unit # 4 is fully computerized. All functionality is handled by
computer programs. This organization employs about 1500 people, both technical and non-
technical. For this project, the Muzaffargarh economic district was selected. Other reasons for
this location are that there is no spa in this area. At that time, the area like the Multan Division
and D.G. Khan was approximately in central Pakistan. The location can be chosen for security
reasons in war conditions.
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The Water and Energy Development Authority of Pakistan (WAPDA) is an integrated utility in
Pakistan. WAPDA is responsible for the development of the hydroelectric and water sector
project in Pakistan. WAPDA operates through water wings and is responsible for the generation,
transmission and distribution of energy. In addition, it manages the irrigation, water supply and
drainage systems of the country. In addition, it is also responsible for the prevention of water
residues and the recovery of water and saline land residues.
The Water and Energy Development Authority of Pakistan (WAPDA) was established in
February 1958 by a law of the Parliament for the rapid and integrated development and
conservation of the country's water and energy resources. Under the Act, which was amended in
March 1959 to transfer the existing Electricity Division of the Federation Units to WAPDA, the
tasks of research, planning and implementation of projects and projects were transferred to:
As part of subsequent developments, the "1994 Energy Policy", the creation of thermal
power generation projects has been transferred to the private sector. At present 13 companies
work under WAPDA.
• These are:
• • National Transmission and Distribution (NTDC)
• • Four thermal energy companies (GENCO)
• • eight sales companies (discs)
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4. Capacity
“Capacity is the maximum rate of output for a facility”. The facility can be a workstation or an
entire organization.
4.1 PHASE-1:
In phase one there are three units of capacity 210MW. This phase was established by Russia also
called Russia phase.
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4.2 PHASE-2:
In phase two there are two units of capacity 210MW and one unit of capacity 320MW.
So, the total capacity of both two phase is 48000000 units/24 hrs. But this is situation when all
the units are working with their full capacity. But there is little situation
When this type of occurrence. But they utilize their capacity according to the requirement. All
the decisions about the utilization are done at higher level. NPCC Islamabad gives all the
instruction about the utilization. The reason is that all the thermal houses in Pakistan are
connected just a ring topology (the term in networking). When sufficient amount of water is
available the more concentration are given to produce Hydroelectricity because this source of
electricity are much cheap than thermal electricity.
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Week 1 -Boiler
5. Boiler
A vessel that heats the water and converts it into pressurized steam (Saturated Steam).
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• Boiler Shell: This shell is the external cylindrical part of a pressure container.
• Boiler Drum: This is a cylindrical formed space at the base of the water space. The
impurities like mud, sediment, and others will be gathered.
• Strainer: This is a type of device as a filter to hold solid elements letting a fluid to
supply.
• Boiler: This is a surrounded space offered for the fuel combustion.
• Burner: This is one type of device for the beginning of air and fuel into a boiler at the
preferred velocity.
The two drums are associated via two tubes such as down comer and riser. At first, the water is
supplied into the steam type drum with the help of a water pump. Whenever the fuel is burned,
then hot gases will be generated that are permitted to supply in the shell part of the boiler. The
hot gases which are produced by the fuel will replace heat by the water; the water gets changed
into steam. Because, the water temperature increases, the concentration will increase
automatically. Clearly, the concentration of steam will be lesser than the water. Thus, in the
steam drum, the water, as well as steam, gets divided obviously due to variation in concentration.
The flow of hot water at the base of the steam drum will be supplied into header via down comer
tube as well as to heat the water in the header.
In Balanced Draft Boilers, Furnaces equipped with both an FD (Forced Draft) and ID (Induced
Draft) fans. In balanced draft systems, the forced and induced draft fans work together to move
combustion air and flue gases through the furnace. The FD fan is used to regulate the combustion
airflow and the ID fan is used to regulate furnace pressure. Balanced draft furnaces are typically
operated slightly below atmospheric pressure.
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An induced draft fan draws the gases through the flue ducting and the combustion air into the
furnace making high stacks unnecessary. Control is accomplished by regulating the fan speed or
damper operation.
A forced draft furnace uses a fan or blower to force combustion air through the system. Control
is accomplished by regulating the fan speed or damper operation. This type of furnace is
operated slightly above atmospheric pressure. Forced draft furnace must be airtight to prevent
leakage of flue gases into surrounding area.
GRC fan forced the exhaust back into the burner so that complete combustion is achieved, and
the un-burnt fuel or gases is removed from the exhaust.
5.8 Superheater:
The Steam Superheater is a coil type heat exchanger which is used to produce superheated
steam or to convert the wet steam to dry steam, generated by a boiler. It is different from
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a boiler in a way that, boiler utilizes both sensible heat as well as latent heat to convert water into
steam while super heater utilizes only sensible heat to superheat the steam in order to increase its
enthalpy.
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5.11 Deaerator:
A deaerator is a device that is widely used for the removal of oxygen and other dissolved gases
from the feed water to steam-generating boilers. In particular, dissolved oxygen in boiler feed
waters will cause serious corrosion damage in steam systems by attaching to the walls of metal
piping and other metallic equipment and forming oxides (rust). Dissolved carbon dioxide
combines with water to form carbonic acid that causes further corrosion. Most deaerators are
designed to remove oxygen down to levels of 7 ppb by weight (0.005 cm³/L) or less as well as
essentially eliminating carbon dioxide.
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Figure 8: Deaerator
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6.2 Working:
The hot water is usually caused by air conditioning condensers or other industrial processes. That
water is pumped through pipes directly into the cooling tower. Cooling tower nozzles are used to
spray the water onto to the "fill media", which slows the water flow down and exposes the
maximum amount of water surface area possible for the best air-water contact. The water is
exposed to air as it flows throughout the cooling tower. The air is being pulled by a motor-driven
electric "cooling tower fan". When the air and water come together, a small volume of water
evaporates, creating an action of cooling. The colder water gets pumped back to the
process/equipment that absorbs heat or the condenser.
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This is the pump to send cooling water to the condenser. It receives water from for bay. Before
sending water to the condenser water is passed through a screen filter to remove impurities
.circulating water pump is centrifugal pump having vertical shaft.
Type Y1600-12/2150
Rated Voltage 6.6 KV
Rated Current 182 A
Rated Speed 372 RPM
Rated Power 1600 KW
Rated Frequency 60 Hz
Capacity 16000 m3/H
Power factor 0.9
Table 2: CW Pump Specifications
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The motor of pump is oil cooled and air cooled .Stator winding connection is Y. the rated
frequency is 50
Hz and no. phases are 3. Water from the circulating water pump is passed through these pipes it
consist of ideal flow gate valve during start of pump this valve remain open until non return
valve is not fully open.
As non-return valve fully open this valve will be closed. Vent valve is used to remove bubbles
and air from pipe line this is low pressure and high discharge flow pump.
External treatment is the reduction or removal of impurities from water outside the boiler. In
general, external treatment is used when the amount of one or more of the feed water impurities
is too high to be tolerated by the boiler system in question.
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To purify the water from makeup tank there is a water treatment plant, where this water passes
through different stages to remove its impurities. The block diagram of this plant is given below.
The raw water in this plant passes from 6 different stages which are:
• Mechanical Filters
• 1stStage of Cation Filter
• De-Gasifier
• Anion Filter
• 2nd Stage of Anion Filter
• Mixed Bed Filter
7.6 De-Gasifier:
De- gasifier or de- carbonizes are used to remove CO2 gas from the water. For this purpose there
are two main chambers where water is showering from the top and air is entered form the bottom
by fans. This air interacts with the carbon ions in water and makes CO2 gas, which moves out
from the top side of chamber. And the water collected in the storage tank, located below the
chamber.
Calorify water is passed through anion bed exchanger +ve charge disappear. Water is sent to
anion filter form decarbonized water tank, using pumps. There are four filters in which one is
used and other are for backup. Each filter has capacity of 90T/h. Na OH is introduced in water to
remove silica and other anions.
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8. Valve:
A device for controlling the passage of fluid or air through a pipe, duct, etc. especially an
automatic device allowing movement in one direction only.
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Types of Valve:
8.1 Gate Valve:
Gate valves (also known as knife valves or slide valves) are linear motion valves in which a flat
closure element slides into the flow stream to provide shut-off. These valves are used to control
high pressure and also prevent leakage. A drawback of this valve is it operates slowly.
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1. 12.1 HP (High Pressure) Turbine: High pressure (182 bars) and High temp. (547
Degrees) of steam at inlet. The steam has 300 Degrees temp. and 34 bars at outlet.
2. 12.2 IP (Intermediate Pressure) Turbine: From HP turbine the steam goes to a reheater
and the temp. Is raised up to 547 Degrees and 29 bars pressure is kept to avoid the back
pressure of steam in HP turbine.
3. 12.3 LP (Low Pressure): Turbine: From IP turbine the steam goes to LP turbine without
reheating because there is no need of further raise in temp. and pressure.
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its density is only about 7% of the density of air resulting in fewer wind age losses due to the
rotor churning up the air in the machine and its thermal capacity is 10 times that of air giving it
superior heat removal capability.
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18. Condenser:
The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be
pumped. In TPS Muzaffargarh surface type condenser is used. The surface condenser is a shell
and tube heat exchanger in which cooling water is circulated through the tubes. The exhaust
steam from the low pressure turbine enters the shell where it is cooled and converted to
condensate e (water). The cooling water is return to the cooling tower and condensate is
collected in hot well.
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This extracts the greatest amount of energy from the steam to maximize the power output of the
turbine. The steam, at this low pressure (vacuum) condenses at 65°C. The condenser operates
under high vacuum which occurs due to the condensing of the steam. (This causes a huge
volume decrease in that the water, When converted to steam expands by 1,800 times. When
condensing, it therefore occupies a volume 1,800 times LESS as water). The water formed is
pumped back to the Boilers for re-use. The Cooling towers don't cool this water as its treated
water specifically used for steam generation. A separate Cooling Water System is used for the
surface condensers and other heat exchange (cooling) systems throughout the Power Station. It's
this water that is cooled by the towers and is also recycled from the tower collecting basin to the
Cooling Water distribution pumps.
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• Split Muff Coupling: In split muff coupling, the sleeve or muff isn’t a single
different part instead it is split into 2. The muffs are semi-cylindrical in
shape which then fits over the shaft. Threaded holes are provided on the muffs so
that both the shafts can be joined with steel bolts or studs. The special feature of
this coupling is that it can be assembled and disassembled without changing the
position of shaft.
Applicat ion-
They are used for medium to heavy dut y load with moderate speed.
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• Bush Pin Type: It is also like Flange Coupling. The only difference between them
is the usage of rubber bushings. Slightly thick rubber bushings are designed so
that the studs or bolts perfectly fit inside it and bushing fits perfectly inside the
holes provided.
The major advantage of using this coupling is that it can be used for slightly
misaligned shafts. The rubber bushings add a certain amount of flexibility to the
coupling which also helps to absorb shocks and vibrations.
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• Oldham’s Coupling: Oldham’s coupling is used to connect the two parallel shafts
when some eccentricity is present between two rotating shafts. In this the two
misaligned shafts have disc shape flanges with rectangular slot at the middle.
Both the flanges have slot cut which is at right angle to each other. In between
two shaft a circular disc assembled having tongue on both side at right angle to fit
between the slots of flanges. When shafts rotate then the tongue of the flanges
slides into the recess of the flanges of the shafts. The middle disc rotates about its
center but both the misaligned shafts rotate their own axis by means of sliding
tongue into the grooves which results the center of the middle disc traces a
circular orbit. The maximum sliding velocity of the both the tongue in the slots
will be the peripheral velocity for the middle disc at midpoint along the circular
orbit.
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24. Bearing:
The word bearing is derived from the verb “to bear”. A bearing is a machine element that allows
one part to bear another. The main functions of bearings are
As the name implies, in this bearings the bearing surface is in contact with moving surface or the
shaft which produces more friction. These bearing are made up of cast iron, bronze, brass, baibit
and white metal having hollow round shape. Lubricant is used for slow moving and heavy
weighted running on shaft. These bearings to support crack shaft, rocker arm of IC engine.
Friction bearing are also subdivided into following types
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It is a simplest hole made in cast iron to support the shaft and form running fit. These are made
up of cast iron or bronze in the form of bush and press-fitted in fabricated or cast iron housings.
This is used for small and light shafts moving at low speed. A hole is provided on its face of
lubrication.
(B.)Split bearings:
Split bearings are same like solid bearings but have an arrangement of split. Split bearings are
made in halves and assembled in special plumber blocks. It has collar on its external surfaces and
also made in two parts as shown in figure.
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It consist mainly two parts. The first one is cast iron block and other is bush. These bearing bush
are made up of brass or any other soft material in round shape. To protect it from moving, a
screw is fixed at one end and this screw is fixed half to the bush and half in block.
The main purpose of these bearings is to minimize the friction in bearing. Due to this reason, the
speed of an object increases and friction and temperature decreases. Such bearing have long life.
These bearing also sub-divided into following categories.
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A ball bearing is a rolling element bearing that used ball to maintain the separation between the
bearing races. The width of these bearing is smaller than the bore diameter or ball. On the basis
of load and groove cut, ball bearings are classified in the following types.
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(B.)Roller bearings:
Roller bearings are available with the grooved race in the outer and inner members. Roller
bearings are capable of carrying the journal (radial) loads. It can work with greater load than ball
bearings. To use this bearing, race is required to be locked. On the basis of uses, roller bearings
are classified in following types.
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In this type of bearing, the loading is at right angles to the bearing axis, such that bearing is
installed perpendicular to the axial line of the shaft.
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Thank you
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