SUMMER INTERNSHIP REPORT JUL19-AUG19

(6 WEEKS)AT JPCL JAMSHORO, SINDH

SUBMITED BY: TAQI HAIDER (3455-2016)

DEPARTMENT OF ELECTRICAL ENGINEERING,

INDUS UNIVERSITY KARACHI

PROGRAM: BE ELECTRICAL ENGINEERING

 PREFACE
It is well evident that work experience is an indispensable part of every professional course. In the same
manner practical training in any organization is a must for each and every individual the engineering
course. The rationale behind visiting the power plant and preparing the Project Report is to study the
electrical overview, mechanical overview, various cycles and processes (Steam Generation, Turbo
Generation, Synchronization, etc.) of the power generation and details of control and instrumentation
required in Thermal Power Plant.
We have carried out this training under well experienced and qualified engineers and technician from
various departments’ viz. Electrical, Mechanical and Control and Instrumentation departments. We have
taken the opportunity to explore the Electrical Department, its use, necessity in power plant and
maintenance of various instruments used for monitoring and controlling the numerous processes of
power generation.
We have tried our best to cover all the aspects of the power plant and their brief detailing in this project
report. All the above mentioned topics will be presented in the following pages of this report. The main aim to
carry out this training is to familiarize ourselves with the real industrial scenario, so that we can relate with
our engineering studies.

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 Acknowledgement

First I would like to thank Sir Rizwan Arian, for giving us the opportunity to
do an internship within the organization. For us it was a unique experience
to be in thermal power station Jamshoro and to study an interesting
working of plant. It also helped to get back interest in research and to have
new plans for our future career. We would like to thank all the people that
worked at TPS Jamshoro with their patience and openness they created an
enjoyable working environment. Furthermore we want to thank all the
Engineers and workers, with whom we did the fieldwork. We experienced
great things together At last but not least we would like to thank Sir
Mahindar Kumar for his kind guidance and help .He really made our work
nice and great.

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Contents
INTRODUCTION................................................................................................................................. 5
Pakistan Electric Power Company (PEPCO)....................................................................................5
Jamshoro Thermal Power Station........................................................................................................6
LOCATION.......................................................................................................................................... 6
Overall Thermal Power Plant Layout...................................................................................................9
Water Cycle......................................................................................................................................... 9
Mechanical Components:.................................................................................................................. 10
Boiler:............................................................................................................................................. 10
Steam turbine:................................................................................................................................ 11
Condenser:..................................................................................................................................... 14
Feed water pump:.......................................................................................................................... 16
Cooling tower:................................................................................................................................ 18
FD and ID fans:.............................................................................................................................. 19
Flue Gas Stack (Chimney)............................................................................................................. 19
Conclusion.......................................................................................................................................... 21

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 INTRODUCTION

Electricity generation is the process of generating electric power from

sources of energy. Electricity is most often generated at a power station by
electromechanical generators, primarily driven by heat engines fuelled by
chemical combustion or nuclear fission but also by other means such as the
kinetic energy of flowing water and wind. There are many other
technologies that can be and are used to generate electricity such as solar
photovoltaic and geothermal power. In Pakistan the abundance of gas and
oil leads to establishment of thermal power stations and governing bodies
namely PEPCO, IPP’s and PAEC power acts as pioneers in the generation of
electricity.

Pakistan Electric Power Company (PEPCO)

The factors responsible for the shift in policies were: generation capacity
could not be increased to meet demand; WAPDA's growth caused
inefficiencies, 'demand suppression' and high tariff policy, proliferated
theft. All these factors, over the years, adversely affected WAPDA's
financial condition. As part of this program WAPDA's functions under its
Water Wing and Power Wing were to be segregated. It was previously
envisaged that all power generation, hydel as well as thermal, would be
corporatized. However, later on it was decided that the hydel generation
should remain part of the Water Wing or the remaining WAPDA. PEPCO has
prepared the conceptual framework and is following a comprehensive
strategy whereby WAPDA's vertical-monolithic Power Wing has been
restructured into twelve (12) distinct autonomous entities under
Companies Ordinance 1984.These are three generation, one transmission
and eight distribution corporate entities.

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 Jamshoro Thermal Power Station
LOCATION
Thermal Power Station Jamshoro is situated in District Jamshoro (Sindh) 5
Km North-West of the village of Jamshoro on Indus High-way at the right
bank of River Indus at city of Mohra Jabal, about 18 Km from center of
Hyderabad. The city of Karachi is approximately 150 Km South-West of
Jamshoro connected with Super-Highway.

A thermal power station is a power plant in which heat energy is converted

to mechanical power first and then it is converted into electrical power.
Thermal Power Station (TPS),Jamshoro.is.situated.in District Jamshoro
( Sindh ) 5KmNorth-West of the village of Jamshoro on Indus High-way at
the right bank of River Indus at Mohra Jabal, about 18 Km from Centre of
Hyderabad. The city of Karachi is approximately 150 Km South-West of
Jamshoro connected with Super- Highway. This Power Station comprises off
our unit shaving total rated capacity of 880 MW. Unit No. 1250 MW Japan
origin is Furnace oil fired, whereas Units 2, 3 and 4 of 210 MW China Origin
each are dual fired i.e. Gas and Furnace Oil.

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Figure 1 unit 2 (Chinese)

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Overall Thermal Power Plant Layout

Water Cycle
Mechanical Components:
Boiler:

Boiler is major component of steam turbine power plant. It is also called

steam generator. It is the component which generates the steam from
water by transferring heat of combustion (of fuel) to water. This plant
contains four boilers as it has only four units. The type of boiler is water
tube boiler. (Water circulates inside the tubes and furnace is below these
tubes.)

Specifications of boiler unit no 1:

Max evaporation=795,600kg/h
Steam max temp=540C
Heating surface of SH and economizer=17533 Furnace
type=natural circulation pressurized furnace.
Steam turbine:

Steam Turbine is the heart of a Thermal Power Station. In order to turn the
Steam Turbine, we must supply high temperature and high pressure steam at
the inlet of the turbine. As the turbine absorbs energy from the steam, its
temperature and pressure drops toward the out let. The rotor blades of steam
turbine are having Aero foil shape for converting maximum amount of
thermal energy of steam into mechanical energy of turbine rotor. High Capacity
Power Plants use different stages of Steam Turbine as:

a) High Pressure(H.P)Turbine
b) Intermediate Pressure(I.P)Turbine
c) Low Pressure(L.P)Turbine

The steam first enters at the inlet of HP Turbine with a temperature and
pressure of 540𝑜C and 132kg/cm2 respectively. At the out let of HP Turbine, the
temperature drops to 350𝑜C. For increasing the efficiency of Thermal power
plant, we add more heat to the steam through Re-Heaters situated in Boiler.
After Reheating, the temperature of steam is recovered to the initial position.
Now the reheated steam is sent to the IP Turbine for further processing. Then
from IP Turbine, the steam goes to LP turbine for final turbine processing. At the
out let of LP Turbine, the temperature and pressure of steam has dropped to
0.2kg/cm2 and 50𝑜 C respectively. A condenser is set below the LP Turbine, where
the low pressure and low temperature steam is transferred. The rotor of Steam
Turbine will rotate at a speed of 3000 rpm.
Total 8 Extractions are drawn from Steam Turbine. 2 from HP, 4 from IP, and
2 from LP steam Turbine. These are drawn for pre-heating purposes.

Figure 2 turbine interior

 Figure 3 turbine exterior

Figure 4 turbine and generator

Condenser:

The low pressure and low temperature steam from the out let of LP steam turbine
enters the inlet of Condenser. The condenser condenses the steam from the exhaust
of the LP turbine into liquid to allow it to be recycled. A surface condenser is used at
TPS, Jamshoro. The surface condenser is as hell 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
(water) by flowing over the tubes. The pressure inside the condenser is maintained
at 0.2kg/cm2.The condenser generally uses Circulating Cooling Water from a Cooling
Tower to reject waste heat to the atmosphere.
After that, the condensate is stored in a Hot Well from where, it is pumped to
the LP (Low Pressure) Heaters through Condensate Pump. 4 LP heaters are
Used for each Unit at TPS, Jamshoro. They are used to pre-heat the condensate at Low
pressure than atmospheric pressure and raise the temperature from 50 C to 150
C. These 4-LP heaters work on the 2-Extraction lines from LP and 2 from IP steam
turbines. After pre-heating of Condensate at low pressure, it is sent to the
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. We
take 1-Extraction IP steam Turbine for the processing of Deaerator. This whole
cycle is Condensation Cycle
Figure 5 pipes from condenser
Feed water pump:

It is a device used to provide feed water coming from condenser into

boiler drum at a certain height and required flow rate. The plant contains
four feed water pump. FDP of unit 1iscentrifugal type and with power of
3800 kW, capacity of 485 ton/h rand 1485 rpm speed.
Cooling system for pump such as lubrication or water is also available
to cool bearings and rotating parts.

Figure 6 water pump (Chinese)

Figure 7 Water pump (Japanese)
Cooling tower:

The cooling tower is also called heat exchangers. These are used to cool
the hot water coming from condenser with help of air and pump. This
water also helps in cooling the pumps bearings and other heated parts of
plant. Hence this water is circulated around the condenser and cooling
tower. Cooling towers contain number of fans that are used to suck air
and that air is passed around the tubes that contain the hot water. Total 2
Cooling Towers are used at TPS, Jamshoro: 1-Japanese and 1-Chinese. The
Japanese one have 6 CT (Cooling Tower) Fans and the Chinese one have 12

CT Fans.
Figure 8 cooling towers of Chinese unit 2
FD and ID fans:

These are electrically operated fans, used to force gaseous. FD fan is used
to force incoming air into furnace, travelling from air pre heater while ID
fan is used to obtain required draught. In this power plant unit 1 contains
only ID fan and allow the units contain both ID and FD fans (balanced
draught).

Flue Gas Stack (Chimney)

The Flue Gases leaving the Boiler contains nitrogen along with
combustion products carbon dioxide, sulphur dioxide, and nitrogen
oxides. The gas travelling up the Flue Gas Stack may by this time have
dropped to about 50°C. Total 2 Flue Stacks are present at TPS, Jamshoro
and each of the mare 500 ft. high. They are made that much high because
we cannot disperse these gases at the lower level as they are very
dangerous for human health. That’s why they are made that much tall to
disperse the remaining flue gas components up in the atmosphere. The
ID (Induced Draught) Fans are used to take the Flue Gases out from the
Boiler and up in the atmosphere through
Flue Stack.
Conclusion
It was such an ice experience dealing with professionals and learning from
their experience at thermal power station. We have felt immense
pleasure at our internship and were very excited to know about different
interesting procedures and the all new equipment’s for us that we have
seen here. We again thanks a lot to Sir Rizwan Arain who has really
committed himself to us for our betterment. It was an experience which
we will never forget and it will help us in future achievements

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