SIX WEEKS SUMMER TRAINING REPORT

On
(Thermal Power Plant)

Submitted By:
JAGDEEP SINGH
Registration No: 11112720
Section: E3109
Programme: Bachelor of Technology
(ELECTRICAL AND ELECTRONICS)

Under the Guidance of

MR. GOURAV GARGI
(SUB DIVISION OFFICER ).

School of Electronics and Electrical Engineering

Lovely Professional University, Phagwara, Punjab

(June-July, 2014)

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 DECLARATION

I here by declare that I have completed my six weeks summer training at GHTP LEHRA
MOHBBAT, BATHINDA from June 3, 2014 to August 01, 2014 under the guidance of Mr.
GOURAV GARGI (Sub Division Officer ). I declare that I have worked with full dedication
during these six weeks of training and my learning outcomes fulfil the requirements of
training for the award of degree of Bachelor of Technology (EEE), Lovely Professional
University, Phagwara, Punjab.

JAGDEEP SINGH
REG NO: 11112720

DATE: 04-08-2014

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 ACKNOWLEDGEMENT

This project report could not have been completed by my efforts alone. I would like to
acknowledge and extremely heartfelt gratitude to the following persons who have made the
internship report on GHTP. I am thankful to my mentor Mr. GOURAV GARGI (Sub
Division Officer ). for his extreme support. I would also thank Mr.
Hardeep Singh, Mr.Rohit Jain, Mr.Hitesh, Mr. Arpit and Mr. Ashok Agnihotri for helping
me to learn as much as possible from this internship.

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CONTENTS Page No.
1 .Brief History Of Plant ………………………………….. 5
 General Project Information

2.Different parts of power plant:-

 Switchyard ……………………………………………………… 6
 Switch Gear …………………………………………………….. 9
 Power Transformer …………………………………………….. 13
 Generator ………………………………………………………. 16
 Rated protection in turbo generator …………………………...... 22
 ESP ……………………………………………………………. 23
 CHP ……………………………………………………………. 25
 AHP …………………………………………………………… 28
 WCP …………………………………………………………… 30

3.) Learning Outcomes……………………………………… 33

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1. BRIEF HISTORY OF PLANT
Ever widening gap between the power demand and its availability in the state of Punjab
was one of the basic reasons for envisaging a thermal plant at 'Lehra Mohabbat' Dist.
Bathinda. The other factors favouring the installation of this thermal were low initial cost
and less generation period as compared to hydro electric generating stations, its good
railway connection for fast proximity to load center. GURU HARGOBIND THERMAL
PLANT has units each of capacity is 210 MW. The first unit was commissioned in end of
December 1993 and Ilnd unit was commissioned in then end of June 1994.

The power availability from the plant now meets 20-25% of the total power requirement in
Punjab. It has gone a long way in ushering prosperity in the state by emerging a large
number of agricultural pumping sets, more industrial connections, 100% rural
electrification, increased employment potential reliability and improvement in continuity of
supply and system voltage and removal of power cuts to a great extent. It has also led to
fast development and improvement of environment in area around Dist. Bathinda by
providing employment to about 3000 persons.

GENERAL PROJECT INFORMATION

 Owner Punjab State Electricity board
 Name of Project Guru Har Gobind Thermal Plant
 Site Location Between 29 Km and 32 Km, Mile
stone on Bathinda Barnala Road
 Installed Capacity 2 x 210 MW, 2 x 250MW
 Total Land Required 1000 Acres
 Total Cost of project 65000/- Lac
 Cost per Kw Installed 15,476 Rs.
 Generation Cost 112 pasia / KW
 Coal Consumption/Year 13,86,000 Tonnes-
 Cost of Coal/Tonnes 680 Rs
 Ash Production/Year 4,85,000 tones
 Height of Chimney 220 Meter Multi Flue
 Source of Water Bathinda Branch of Sirhind Canal
 Ash Content 35% of total Coal

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2. DIFFERENT PARTS OF PLANTS
A). SWITCHYARD
Electrical energy management system ensures supply of energy to every consumer
at all times at rated voltage, frequency and specified waveform, at lowest cost and
minimum environmental degradation. The switchgear, protection and network automation
are integral parts of the modern energy management system and national economy.
The modern 3-ph, 50 Hz, AC interconnected system has several conventional and non-
conventional power plants, EHV AC and HVDC Transmission system, Back to Back
HVDC coupling stations, HV Transmission network, substations, MV and LV
Distribution systems and connected electrical loads. The energy in electrical form is
supplied to various consumers located in vast geographical area, instantly, automatically,
and safely with required quality at all times. The service continuity and high quality of
power supply have become very important.
The substation at GHTP Lehra Mohabat has only one 220 KV switchyard. There are two
output units each having a capacity of 210 MW. The generating voltage is limited to
15.75 KV and this voltage as stepped up by two-generator transformer 15.75/220 KV
manufactured by BHEL. A part of 15.75 KV supply is fed to unit auxiliary transformer,
which is stepped down to voltage 6.6 KV which is used to run the major auxiliaries of the
plant.
After step up, the 220 KV output from the generator transformer is fed to either of the two
bus bars through relays and circuit breakers and these are connected to various feeders
through various equipments.

Function Of Different types of Equipment:-

a) BUS-BARS: -
Bus bar is a term used for main bar of conductor carrying an electric current to
which many connections may be made. These are mainly convenient means of
connecting
switches and other equipments into various arrangements..

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b) LIGHTENING ARRESTORS: -
These are equipments designed to protect insulators of power lines and electrical
installations from lightening surges by diverting the surge to earth and instantly
restoring the circuit insulation to its normal strength with respect to earth.
c) CURRENT TRANSFORMERS: -
The main purpose of current transformer is to step down the current to a level that
the indicating and monitoring instruments can read. When rated current flows
through its primary winding, a current of nearly 1 amp will appear in its secondary
winding.
The primary is so connected that the current being passes through it and secondary
winding is connected to an ammeter. The CT steps down the current to the level of the
ammeter.

d) POTENTIAL TRANSFORMER: -
These are used to step do the voltage to a level that the potential coils of indicating
and monitoring instruments can read. These are also used to feed the potential
coils of relays. The primary winding is connected to the voltage being measured
and the secondary winding to a voltmeter. The PT steps down the voltage to the
level of the voltmeter
e) WAVE TRAP: -
Wave trap is used to prevent high frequency signals from entering other zones.
f) ISOLATORS: -

One of the cardinal measures for ensuring full safety in carrying out work on equipment in
electrical installations is to disconnect reliably the unit or the section on which the work is
to be done from all other live parts of the installation. To guard against mistakes, it is
necessary that apparatus, which makes a visible break in the circuit such as isolators,
should do this.
Isolators do not have arc control devices therefore cannot be used to interrupt currents
at which the arc will be drawn across the contacts. The open arc in these is very
dangerous, in that it will not only damage the isolator or the equipment surrounding it
but will also cause the flashover between the phase in other words, it will result in
short circuit in the installation i.e. why isolators are used only for disconnecting parts

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 after de-energizing them by opening their respective circuits by use of their circuit
breakers.

g) EARTHING SWITCHES: -
Earthing switch is used to discharge the voltage on dead lines to earth. An
auxiliary switch to provide interlock always accomplishes it.
h) CIRCUIT BREAKERS: -
Circuit breakers are mechanical devices designed to close o open contact or electrical
circuit under normal or abnormal conditions. CB is equipped with a strip coil directly
attached to relay or other means to operate in abnormal conditions such as over power etc.
In GHTP three types of CB are used. SF6 CB is used to control 220 KV in switchyard.
VCB are used to control 6.6kv in switchgear & ABCB are used to control 415KV in
switchgear.
In sulphar puffer type SF6 CB is filled with SF6 gas at single pressure (4to6kgf/cm2). The
pressure and gas flow required for arc extinction is obtained by piston action.
In double pressure type SF6 CB the gas from high-pressure system is released to into low-
pressure system over the arc during the arc quenching process.

Type of Circuit Breakers

 DC -220 Volt : MCCB
 415 Volt : Air Circuit Breaker (ACB)
 6.6 KV : Vacuum Contactor or Vacuum Circuit Breaker
 11 KV : Vacuum Contactor or Vacuum Circuit Breaker
 220 KV – SF6 Circuit Breaker
i) RELAYS
Relay is a device by means of which an electric circuit (trip or alarm circuit) is
controlled (closed) by change in the other circuit. Relays are automatic. The function
of relay in power supply system is to recognize a start out and to initiate the operation
of CB or other devices to isolate the defective elements with minimum disturbance to
the normal power supply system. The must operate at required speed and stability to
prevent the current and voltage to exceed their limits.

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B) SWITCHGEAR
The switchgear constitutes all parts or equipments of power plant whose function is to
receive and distribute electric power.
It is the combination of electrical relays, fuses, circuit breaker and contactor that use to
isolate or control electrical equipment

Functions of Switchgear: -
The functions performed by switchgear are listed below: -
 To facilitate redistribution of load, inspection and maintenance of system.
 To localize the effects of faults by operation of protective equipment so
automatically disconnect faulty part from the system.
 Its main function of protection, isolation and distribution of power supply to
different section of power plant

 The protective relays are connected in secondary circuit of CT and PT. The relay
senses the abnormal condition and closes the trip circuit of the associated circuit
breaker

The switchgear has the responsibility of transmitting the power from the generator to the
grid. However plant also needs power for its working. It is mandatory not to use more
than 10% of the power developed by the plant. So that all the auxiliaries and lightening
system of the plant must be designed in such a way that there consumption is in the limit.
There are two bus bars placed in ducts, which supply power to the switchgear and are fed
by two station transformers ST-I and ST-II. The rating of these identical bus bars is 6.6
KV, 3150 Amps, 50 Hz. These are known as C-I and C-II station buses respectively. The
material of conductor is Aluminium. C-I station bus feeds US-IA & US-2A buses and C-
II feeds US-IB & US-2B buses. C-I & C-II buses are also interlinked. These unit service
buses feed the different kinds of load.
The auxiliary voltage for the ac supply system is 6.6 KV and 415 V. 6.6 KV supply
system is provided with high resistance grounded neutral with provision of alarm/ trip.
415V auxiliary supply system has solidly/high resistance earthed neutral. All the electric
motors of 150 KW rating or below are rated at 415 V and motors above 160 KW are rated
at 6.6 KV.

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Panel Rating of Switchgear:
• DC -220 Volt : 25 KA for 1 Sec
• 415 Volt : 50 KA for 1 Sec & Solidly Earthed.
• 6.6 KV : 40 KA for 3 Sec & Earth Fault Current limit to 300 Amp
• 11 KV : 40 KA for 3 Sec & Earth Fault Current limit to 300 Am
• 220 KV - 40 KA for 1 Sec & Solidly Earthed

GENERAL ELECTRICAL SUPPLIES IN THE PLANT

Electrical Auxiliary System
I. AC Auxiliary supply system
II. DC supply system

AC auxiliary supply system is used to feed all the AC auxiliaries installed in the plant.
The DC supply system which consists of 220 V DC, 110 V DC, +/- 24 V DC, 48 V DC
etc. is used for control supplies as required for system control and protection equipment.

I. ELECTRICAL AC AUXILIARY SUPPLY SYSTEM

A general station apart from generating the electrical supply needs some electricity to
supply to its auxiliaries. There are two levels of voltage at which the supply is given to
the auxiliaries: -
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  6.6 KV level (H.T. system)
 415 V level (L.T. system)
Scheme of connection:
Unit principles of operation is adopted for auxiliary power supply i.e. auxiliaries
connected with the boiler and turbine of a particular unit are supplied by the unit auxiliary
section.
H.T. System (6.6 KV System)
6.6 KV, 500 MVA, switchgear receives its supply from medium voltage transformers
and feed H.T. load of the plant and the L.T. load through various L.T. transformers.

In this system we have buses with ratings of 6.6 KV having resistance grounded
neutral with provision of alarm trip. A circuit breaker is used for switching incoming
as well as outgoing supply from the buses. All the motors of 150 KW or above are
rated for 6.6 KV systems. We have nearly identical arrangement for H.T. panels for
each feeder or incomer

H.T. SYSTEM BUS

1. Station buses
2. Unit buses

II. DC SUPPLY SYSTEM

In this system each unit has a 220 V DC supply buses again in duplicate connected
through a bus coupler. The various supplies in the DC system are: 220 V DC, +/- 24 V
DC, and 48 V DC. These supplies are used for the control equipment such as pick relays
etc.
Each DC comprises of the following:

• Storage batteries (bank) are of lead acid tie having battery cells of high discharge cell
performance each of 2 V.
• Battery charger- Battery chargers are of static type and are capable of trickle charging
and boost charging and simultaneously supply requisite load. Adequate stand by
provisions are made in case of outage of chargers.

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• Distribution and sub-distribution boards- The DC distribution and sub-distribution
boards have compartmental, draw out type construction, housing fuses and switches
for various feeder requirements.
The battery rooms are well ventilated and lighted with adequate provisions for expelling
acid fumes and hydrogen gas out from the battery room.

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C) POWER TRANSFORMERS
A device that transfers electrical energy from one circuit to another through inductively
coupled electrical conductor

Power Transformer:- Used in transmission network of higher voltages (220 kV, 66 kV,
33kV,22kV).

Distribution transformers: -Used for lower voltage distribution networks (11kV, 6.6 kV,
3.3 kV, 440V).

Voltage level used in GHTP :-220KV,66KV,33KV,11KV,6.9KV,415V

Generator Transformers: -
Power from each generator is stepped up to 220 KV by 810 MVA, 50 Hz and 3-phase
generator transformer with offload tap changer. There is one GT for each unit.

Technical Data
S.No. Particulars Specifications
1. Make BHEL
2. Type of cooling ONAN ONAF
OFAF

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 3. Rating HV (MVA) 125 180
LV (MVA) 250

4. No load voltage
HV (KV) 230
LV (KV) 15.75
5. Line current HV (A) 314.13 452.37
628.30
LV (A) 4587.5 6606.1
9175.1
6. Temp. rise of oil (oC) 45 45 45
7. Temp. rise of wdg. 50 50 50
(oC)
8. Phase 3
9. Frequency 50
10. Connection symbol YND1
11. Ambient temp. (oC) 50
12. Total weight 254290
13. Oil quantity (lt) 54000

Station Transformer: -
There are two station transformers one for each unit. ST takes power from grid at 220
KV and steps it down to 6.6 KV. At the time of starting all the auxiliaries is supplied
from ST when alternator are synchronized and starts producing power, about 80 % of
load is shifted to the UAT. Only load that requires the uninterrupted supply is left
connected to ST.

Unit Auxiliary Transformer:-

A part of the electrical energy generated is used to feed auxiliaries through Unit
Auxiliary Transformer (UAT). There are two UATs per unit.

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15
 D)GENERATORS
The generator is two-pole type with cylindrical rotor using direct water-cooling of stator
winding and direct hydrogen cooling of rotor winding. The losses in the other parts of
generator such as stator iron losses, friction & winding losses are removed by hydrogen
circulating in casing. The generator stator frame is of pressure resistant and gas tight
construction with four horizontal coolers in the frame itself.
STATOR :-
The stator of the generator mainly consists of Stator body, Stator core, Stator winding and
gas coolers etc. The stator body is a totally enclosed gas tight fabricated structure. It is
designed mechanically to withstand at internal pressure and forces as a result of unlikely
event of explosion of hydrogen air mixture without any residual deformation. Hydrogen
gas coolers are housed longitudinally inside the stator body.
The stator body with core and stator winding form the heaviest components of the entire
Turbo-generator. It is designed to withstand high internal pressure, which may arise due
to any explosion. Stainless steel pipes are used to connect water to the gas coolers, which
emanate from bottom and emerge out at sidewalls. These pipes serve as inlet and outlet
for gas coolers. There are nine terminals in the terminal box. It is constructed by using
non-magnetic austenitic steel plates. This material eliminates stray losses due to eddy
currents that may result in excessive heating.

STATOR CORE
The stator core is built up of a large number of varnish insulated punching or sections of
thin steel plates (generally 0.35mm to 0.5mm). The use of cold rolled grain-oriented, loss
less steel from which punchings are made can contribute to reduction in the weight of
stator core.
The core stampings are assembled in an inter-leaved manner on core bars. The core
consists of several packets separated by steel spacer for radial cooling of the core by
hydrogen. To ensure a tight and monolithic core, pressing of the punchings is done in
several stages and when completely built, the core is held in pressed condition by means
of heavy non-magnetic steel press rings which are bolted to the end of core bars.
Additional support is provided to the teeth portion by means of non-magnetic fingers held
between the core and the press rings. The press rings are tapered on the face towards the
core, so that an even pressure is exerted over the end surfaces of the core when core bars
are tightened. Copper screens provided between the end packets and press rings reduces
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the end zone heating. In order to isolate the stator body and foundation from magnetic
vibrations of the stator core, the core bars are designed to provide elastic suspension of
core in the stator.

STATOR WINDING

Stator core carries the armature winding. Each stator core must be capable of carrying the
rated current without over heating and the insulation must be sufficient to prevent leakage
current flowing between the phases or to the earth.
The stator has a three-phase, double layer, short pitch, bar type winding having two
parallel paths. Each slot accommodates two bars. The slot lower bars and the slot
upper bars are displaced from each other by one winding pitch and connected by bus
bars inside the stator frame. Each coil side consists of glass-insulated solid and hollow
conductor with cooling water passing through the latter in case of water-cooled
conductors being used in higher capacity units. Water is fed to and from the winding
through Teflon tubes.

ROTOR
The rotor of the generator consists of rotor shaft, rotor windings, retaining rings, fans etc.
The rotor shaft is a single piece forging manufactured from ingots, which are cast by
vacuum degassing process. To ensure that only high quality and defect free forging is

17
used, strength test, chemical analysis and ultrasound tests are carried out during
manufacture. It is subjected to an over speed test at 120% of rated speed for two minutes.
The rotor shaft is more than nine meters in length and slightly more than one meter in
diameter. The high mechanical stresses resulting from the centrifugal forces due to
rotation and short circuit torques call for a high quality, heat-treated steel. The main
constituents of steel are chromium, molybdenum, nickel and vanadium.
The slots, milled on horizontal slot milling machine, house the field winding. The field
winding consists of several coils inserted into longitudinal slots of the rotor body.
The conductors are made of hard drawn silver bearing copper. Apart from low electrical
resistance this grade exhibits high creep resistance so that coil deformations due to
thermal cooling due to start and stop operation are minimum. The rectangular cross-
section copper conductors have ventilating ducts on the two sides thus providing a
channel for hydrogen flow.
SLIP RINGS
The slip rings consist of helically grooved alloy steel rings shrunk on the rotor body
shaft and insulated from it. Both the rings are mounted on a single common steel
bush, which is as insulating jacket pre-moulded on it. The slip rings are provided with
inclined holes for self-ventilation. The helical grooves cut on the outer surface of the
slip rings improve brush performance by breaking the pressurized air pockets that
would otherwise get formed between brush and slip ring surface.

CONDUCTOR CONSTRUCTION

Each bar consists of solid as well as hollow conductors with cooling water passing through
the latter. These conductors are arranged alternatively for increasing current and to reduce
losses. The conductors of small rectangular cross-section are provided with glass lapped
stranded insulation. These are arranged side by side in two layers. The individual layers are
insulated from each other are transposed by 360 degrees to reduce eddy losses.
The transposition provides for mutual neutralization of voltages induced in the individual
strand due to slot cross-field and end-winding field ensures that no circulation currents
will arise. The currents flowing through the conductors is thus uniformly distributed over
the entire bar cross-section. Bar insulation is done with epoxy mica thermosetting
insulation. This insulation is void free and possesses better mechanical properties. This is
more reliable winding insulation, especially for high voltage.

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CORONA PREVENTION
To prevent corona discharges between insulation and the wall of the slot, the insulation is
coated with semi-conducting varnish. Varnish is coated to prevent the formation of creep
age sparks during operation and high voltage test.
The tests to ensure proper quality of bar are following:
 Inter turn insulation test to ensure absence of inter turn short.
 Hydraulic test to ensure the strength of all joints.
 Flow test to ensure that there is no reduction in cross-section area of the ducts
of the hollow conductor.
 Leakage test to ensure gas tightness of all joints.
 High voltage test to prove soundness of insulation.

INSULATION
The individual turns are insulated from each other by layer of glass pre-peg strips on
the turn of copper and baked under pressure and temperature to give a monolithic
interterm insulation. The coils are insulated from rotor body by U-shaped glass
laminated module slot troughs made from glass cloth impregnated with epoxy
varnish.
COOLING FANS
The generator cooling gas is circulated through two single axial flow propeller type fans.
These fans are fitted on either side of the rotor body. The fan hubs are made of alloy steel
forging with free peripheral groove milled on it. Fan blades are machined in the tail
portion so that they fit into the groove of fan hub. Split pins are used along with slotted
nuts to prevent the pins coming out during operation.
GAS COOLERS
Four-gas coolers mounted longitudinally inside generator stator body cool hot hydrogen.
Gas coolers consists of cooling tubes made of brass with coiled copper wire wound on
them to increase the surface area of cooling. Cooling water flows through the tubes while
hydrogen flowing across the cooler comes into contact with external surface of cooling
tubes. Tubes are arranged in staggered form so as to expose maximum surface area to
hydrogen. To remove air from gas coolers while filling them with water, vent pipes are
provided on slip ring sides.

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STATOR WATER-COOLING SYSTEM
The water for cooling the stator winding, phase connections and bushings is circulated
in a close circuit to ensure uninterrupted operation. 100% capacity pumps are
provided to circulate water through the stator winding. In the event of failure of one
pump, an auto starting equipment automatically cuts in the stand by pump. All valves

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and pipes coming into contact with the stator water are made from stainless steel
material.
The operating pump draws water from the expansion tank and after passing through
water coolers, filters and magnetic filter enters the winding and returns back to the
expansion tank.

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E) Rated protection for Turbo generators
Stator earth fault protection:-
1. Generator neutral should be grounded through primary of a distribution
transformer, the secondary of which is loaded with a resistor.
2. It is preferred to provide 100% protection at stator earth fault. If it is
not available, the minimum stator earth fault protection acceptable is
95%.
3. The earth fault current should not exceed 5 amperes for a time of 2
seconds.
Rotor earth fault protection
1. On occurrence of first rotor earth fault an alarm/ signal is provided and
the machine tripped at the earliest but not later than 24 hours.
2. On occurrence of second earth fault the machine is tripped
instantaneously.
Over voltage protection
For over voltage protection over voltage relay is set at 1.2 times the rated voltage of
the machines with a maximum time delay of 2 seconds.

Over load protection

Over load protection is provided to trip the generator on overload and the characteristics
of overload protection relay should match with the overload characteristics of the machine

Stator water-cooling system

The water for cooling the stator winding, phase connections and bushings is circulated
in a close circuit to ensure uninterrupted operation. 100% capacity pumps are
provided to circulate water through the stator winding. In the event of failure of one
pump, an auto starting equipment automatically cuts in the stand by pump. All valves
and pipes coming into contact with the stator water are made from stainless steel
material.
The operating pump draws water from the expansion tank and after passing through
water coolers, filters and magnetic filter enters the winding and returns back to the
expansion tank.

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Excitation system
The static excitation system is installed at GNDTP, Bathinda in order to maintain
system stability. It is necessary to have fast excitation system for large synchronous
machines, which means the field current must be adjusted extremely fast to changing
operational conditions. So due to these reasons the static excitation system is
preferred.
It has the following components: -
 Rectifier transformer
 SCR O/P stage
 Excitation start up and field discharge equipment
 Regulation and operational control circuits

F) ESP (Electrostatic Precipitators):-

The electrostatic precipitators (ESP) are extensively used in the thermal power plant for
removal of fly ash from the electric utility boiler emissions.
An electrostatic precipitators can be designed to operate at any desired efficiency for use as
primary collector or a supplementary unit to cyclone collector. It is often considered
worthwhile to retain an existing cyclone collector as primary collector in the case where the
fly-ash collection efficiencies must be upgraded especially where there is a large amount of
unburnt carbon in the fly-ash. Because the presence of large quantities of the carbon in the
gas can adversely affect the efficiency of the electrostatic precipitator

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Working Principle of Electrostatic Precipitators (ESP):
• The dust laden gas is passed between the oppositely charged conductors and is becomes
ionized as the voltage applied between the conductors is sufficiently large (30kV to
60kV depending upon the electrodes spacing).
• As the dust laden gas is passed through the highly charged electrodes, both negative and
positive ions are formed (positive ions will be a high as 80%).
• The ionized gas is further passed through the collecting unit which consists of set of
metal plates. Alternate plates are charged and earthed.
• As the alternate plates are grounded, high intensity electrostatic field exerts a force on
the positive charged dust particles and drives them towards the ground plate. The
deposited dust particles are removed from the plates by giving the shaking motion of the
plates with the help of cams driving by external means.
• The dust removed from the plates with the help of shaking motion is collected in the
dust hoppers. Care should be taken that the dust collected in the hopper should not be
entrained in the clean gas.

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G) CHP(Coal Handling Plant):-

Raw Coal Wagon- Coal is brought to the site through a Wagon as per requirement.

Wagon tippler-The coal is unloaded from the Wagon and is transported to crushers and for
storage place through conveyor
Junction tower:- JT’s are used where the conveyor has any angular deviation.
Primary Crusher:-The Raw coal is crushed into fine pieces to 45mm grit).
Primary crusher is also called Rotary Breaker since the coal is
crushed by a rotating plate
Secondary Crusher:-The fine pieces of coal is crushed to powder (to 25mm grit.
Mill Bunker-:The 25mm grit coal is crushed into very fine powder for feeding the boiler.
We will have a spare Bunker for each Boiler.

Specification:-
Belt width : 1400mm
Speed : 2.2m/sec
Total install power : 360kw
Capacity : 1350/750 ton/hr
No. of conveyor: 38
ROTARY WAGON TIPPLERS 2 Nos.
BELT CAPACITY 1000 tones/hr
PRIMERY CRUSHE
CAPACITY 1000 tones/hr.
SECONDRY CRUSHE
CAPACITY 1000 tones/hr.
STACKER/RECLAIMER 2 Nos.
VIBRATORY FEEDER 8 Nos.
VIBRATING SCREENS 2 Nos..
BELT FEEDERS 4 Nos

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26
Equipment used in a coal handling plant:-

1. COAL CONVEYOR :
This is a belt type of arrangement. With this coal is transported from coal storage place in
power plant to the place nearby boiler.

2. Pull chord switch

A series of such switches are arranged in series at a 1m distance on the side of conveyor belt.
The power supply to rotor of the conveyor belt is established only if all switches in series are
connected.

3. Vibrating feeder

The coal stored in a huge hub is collected on the belt through vibrations created by the
vibrating feeder.

4. Flap gates

These are used to channelize the route of coal through another belt in case the former is
broken or unhealthy. The flap gates open let the coal pass and if closed stop its movement.

5. Magnetic separator

these are used to separate the ferrous impurities from the coal.

6. Metal detector
These are detect the presence of any ferrous and non-ferrous metal in the coal and sends a
signal to a relay which closes to seize the movement of belt until the metal is removed. It
basically consists of a transmitter and a receiver.

7. Reclaim hopper

Reclamation is a process of taking coal from the dead storage for preparation or further
feeding to reclaim hoppers. This is accomplished by belt conveyors.

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H) Ash Handling System(AHS):-
The ash handling system handles the ash by bottom ash handling system, coarse ash
handling system, fly ash handling system, ash disposal system up to the ash disposal area
and water recovery system from ash pond and Bottom ash overflow. Description is as
follows:
Bottom Ash Handling System:-
Bottom ash resulting from the combustion of coal in the boiler shall fall into the over
ground, refractory lined, water impounded, maintained level, double V-Section type/ W
type steel- fabricated bottom ash hopper having a hold up volume to store bottom ash and
economizer ash of maximum allowable condition with the rate specified. The slurry formed
shall be transported to slurry sump through pipes.
Coarse Ash (Economizer Ash) handling System:-
Ash generated in Economizer hoppers shall be evacuated continuously through flushing
boxes. Continuous generated Economizer slurry shall be fed by gravity into respective
bottom ash hopper pipes with necessary slope.
Air Pre Heater ash handling system:-
Ash generated from APH hoppers shall be evacuated once in a shift by vacuum conveying
system connected with the ESP hopper vacuum conveying system.
Fly Ash Handling System:-
Fly ash is considered to be collected in ESP Hoppers. Fly ash from ESP hoppers extracted
by Vacuum Pumps up to Intermediate Surge Hopper cum Bag Filter for further Dry
Conveying to fly ash silo.
Under each surge hopper ash vessels shall be connected with Oil free screw compressor for
conveying the fly ash from Intermediate Surge Hopper to silo. Total fly ash generated from
each unit will be conveyed through streams operating simultaneously and in parallel.
Ash Slurry Disposal System:-
Bottom Ash slurry, Fly ash slurry and the Coarse Ash slurry shall be pumped from the
common ash slurry sump up to the dyke area which is located at a distance from Slurry
pump house.

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I).Water Cycle System:-
In this process various treatment done on water like pre-treatment of RAW Water,and
sending the filter water for softening and DM Plant and in the last water transferred DM Plant
to Boiler
Specification:-
 The Clarified pump house has 8 pumps- 150KWx3, 9.3KWx2, 30KWx3.
 It has service water pumps, potable water pumps and dual media filter feed pumps.
 There are 2 cooling tower, each having 22 motors of 110KW each (415 V).
 The raw water pump house has 4 pumps of 160KW each.
 Water from raw water pump house goes to cascade aerator.
 3 DM water storage tanks along with 1 main DM water storage tank are there.

 Water by DM transfer pump goes to CMST and then to boiler.

Various water system qualification:-

 Cooling water
 Boiler water
 Consumptive water
DM plant:-
It is the part of plant where total dissolved solids like Ca,Mg, Na,Cl,silka are removed from
the water
There are 8 pumps of150KWx3, 9.3KWx2, 30KWx3 in The Clarified pump house.

There are different types of pumps:-

 service water pumps,
 potable water pumps and
 dual media filter feed pumps.
CONDENSER:
Steam after rotating steam turbine comes to condenser. Condenser refers here to the shell and
tube heat exchanger installed at the outlet of every steam turbine in Thermal power stations.
These condensers are heat exchangers which convert steam from its gaseous to its liquid
state. In so doing, the latent heat of steam is given out inside the condenser .

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COOLING TOWER :
The condensate water after condensation is initially at high temperature. This hot water is
passed to cooling towers. It is a tower in which atmospheric air circulates in direct or indirect
contact with warmer water and the water is thereby cooled. Water, acting as the heat-transfer
fluid, gives up heat to atmospheric air, and thus cooled, is recirculated through the system.

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3.) LEARNING OUTCOME: -

Now we are able to understand and realization about different parts of Thermal Power plant
in GHTP, LEHRA MOHBBAT. Where we got the knowledge about equipments and their
preinciple with their application in daily life of industry.
Working at GHTP LEHRA MOHBBAT, BATHINDA, was a very interesting and
knowledgeable experience. Working here I learnt many things, I met so many people who
were talented in various fields. They helped me understand the working of the thermal and I
was involved in daily workings, which helped me gain a lot of confidence in my work.

In the end I would just like to say that it was a very big opportunity for me to intern in GHTP
LEHRA MOHBBAT, BATHINDA. I am thankful to all the people in GHTP., with whom I
have worked, for teaching me through their past experiences, helping improve my skills and
having faith in me.

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