INDUSTRIAL TRAINING

HELD AT
GURU NANAK DEV THERMAL PLANT BATHINDA
ByName
UNIV. R.No.8th sem
Mech. Engg.

GURU NANAK DEV THERMAL PLANT BATHINDA

INTRODUCTION:Guru Nanak Dev Thermal Plant Bathinda is a coal based

plant. It was established in 19 Nov. 1969.
There are four units that produced 460mw power. Unit
1&2 have 120mw capacity and unit (3&4) have 110mw.
The 1st unit of power plant was started in 1974 & 2nd in
1975 and 3rd and 4th unit was started in 1978 & 1979
respectively.
Cost of Project 115 crores(Original),R&M Cost for U#1 &
U#2=229 Crore. The process of R&M of the unit 3&4 has
been started and work order has been placed on M/s
BHEL for Rs. 465.360 Crore.

 The fuel being used is coal, which is supplied from

Jharkhand /madhya Pradesh which are more than 1500

kms from this power station.
Total daily coal requirement is about 6500MT. (about two
rakes of 58 wagons each) when all the four units are in
operation.
Water supply is given from sirhind canal.
Total hourly requirement of 1 unit of 110mw is nearly
1200 m/hr.
Primary fuel: bituminous coal with calorific value 35004500 kcal/kg
secondary fuel: fuel oil/L.D.O./H.F.O/fo with calorific
value of 9,000 to 10,000 k.cal / liter.

BASIC REQUIREMENTS OF PLANT: WATER

FEUL(COAL)
BOILER
STEAM TURBINE
GENERATOR
ASH HANDLING SYSTEM
UNIT AUXILARIES

BOILER
FURNACE
FORCE DRAFT FAN
SUPERHEATER
REHEATER
TURBINE
CONDENSER
DE-AERATOR
BOILER FEED PUMP
AIR-PREHEATER
COAL MILL
AIR FAN
ECONOMIZER
ELECTROSTATIC
PRECIPITATOR
INDUCED DRAFT FAN
CHIMNEY

Coal is unloaded by electric traction system at Coal Yard

Coal is crushed to finer pieces of order 20 mm
Pulverization of Coal
Coal is send to furnace with the help of FD fan
Steam is generated at 540C and 169 kg/sq.cm
Steam is send to Super heater
Superheated steam is send to turbine
Production of Electricity by the generator coupled with
turbine

COAL HANDLING PLANT

Coal for the power station is received from coal mines

by rail.
Bituminous coal with calorific value 3500-4500 kcal/kg.
Each rake of coal has 58 wagons
The total daily coal requirement is about 6500 M.T.

It is unloaded by means of wagon tipplers.

The bituminous coal is mostly used in the plant.

Coal is unloaded

C.H.P.
The conveyor belts are used for transporting coal from

stock to crusher house.

Where the coal crushes into small pieces & fed to coal
mill.
The coal mill is used for pulverizing the coal.
The coal is converted into powder form.

MAJOR PARTS OF CHP

A. General Working Parts.
B. Emergency Working Parts.
A. General Working Parts are:
1.
Wagon Tippler
2.
Junction Tower
3.
Primary crusher
4.
Secondary crusher
5.
Bunkers
6.
Conveyer System
B. Emergency Working Parts are:
1.
Stacker cum Reclaimer
2.
Manual Handling Hopper
3.
Emergency Reclaimer Hopper

CONVEYOR

Primary crusher
Crushes the coal from 400mm size to 125mm size by

gravity.
Coupling of motor & gear box thro scoop coupling
resulting in smooth start and stop of the crusher.
Then this coal is fed to secondary crusher.

Secondary crusher
Crushes coal from 125mm size to 25mm size.
Motor & gear box are coupled thro scoop coupling for

smooth start and stop of the crusher.

This coal is then fed to coal bunkers.

Coal milling
The coal comes from coal bunker through coal chain feeder.

Where the coal is converted into powder form during the

hammering action of steel balls that revolve in the coal mill.

The mill is driven by an electric motor of capacity 630kW,
990 rpm, 6.6kV through a reduction gear, which reduces
the speed to 17.5 rpm.
40mm diameter
22500 kg
50mm diameter
20000kg
60mm diameter
10000kg
Total Ball Charge
52500kg

Coal mill
The capacity of each mill is 27 T/hr. in case of unit 1 &

2 and 28 T/hr.

BOILER
The water tube boiler is used in the plant. The type of the

boiler is NATURAL CIRCULATION, RADIENT

SINGLE REHEAT boiler.
It consist of large no. of vertical riser tubes embedded in
refractory walls.
The natural circulation takes place in the boiler tubes.
The water is converted into steam at high temp. &
pressure.
RIGHT WALL consisting 130 TUBES.
LEFT WALL consisting 130 TUBES.
FRONT WALL consisting 181 TUBES.
REAR WALL consisting 181 TUBES.

TECHNICAL DATA OF BOILER

Manufacturers
Maximum continuous rating (M.C.R.)
Superheater outlet pressure
Reheater outlet pressure
Final superheater/reheater temperature
Feed water temperature
Efficiency
Coal consumption per day per unit
(Approximate)

B.H.E.L.
375 T/hr.
139 kg/cm
33.8 kg/cm
540C
240C
86%
1400 tones

WORKING OF BOILER

Boiler
Boiler is also called steam generator.
Its main parts & accessories which we studied there are
: Furnace
Boiler Drum
Super heater
Economiser
Air pre-heater

FURNACE
The type of Furnace is BALANCED DRAFT, WATER
WALLS Furnace.

Tangential Firing (Direct firing system)

BOILER DRUM
Boiler drum is made of alloy steel plate of 97mm nominal
thickness and has an outside diameter 1800mm. It is of
fusion welded design with stubs for welding connecting
tubes, feed inlet, chemical closing etc.

SUPER HEATER

BOILER FEED PUMP

It is used for recycling feed water into the boiler at a high
pressure for reconversion into steam.
No. of stages
Delivery capacity
Feed water temperature
Speed
Pressure at suction
Stuffing box
Lubrication of pump

And motor bearing

o Consumption of cooling water
o Driven by

6
445 t/hr.
158C
4500 rpm
8.30 kg/cm
mechanical seal
by oil under pressure
supplied by hydraulic coupling
230 L/min.
3500 KW electric motor.

DEAERATOR
The function of the deaerating header is to remove
dissolved non-condensable gases and to heat boiler feed
water. A deaerating header consists of a pressure vessel in
which water and steam are mixed in a controlled manner.
When this occurs water temperature rise, and all noncondensable dissolved gases are liberated.

TURBINE
It is the prime mover for the generator in power plant.

The potential energy of steam converted into kinetic

energy then the kinetic energy is converted into
mechanical energy. The impulse turbine is used in the
plant & the steam is expanded in the nozzle and
passing from the blades of rotor of the turbine.
Three casing type impulse turbines 110 MW capacity
with 3000 rpm, 29 stages with exhaust pressure 0.08
kg/sq. cm

TURBINE

Turbine is a prime mover for generator in power plant. Type

of Turbine used in unit no. 1,2,3&4 is

Horizontal.
Multi cylinder.
Impulsive Type.

Condensing Type.
Reheat .

29 Stages

TURBINE
The turbine is a compound machine with HP, MP & LP

parts. The HP part is a single flow cylinder and the MP &

LP parts are double flow cylinders. Rigid couplings connect
the individual turbine rotor and the generator rotor.The
turbine accessories are:

Surface condenser
Steam jet air ejector
L.P. & H.P. heaters
Chimney steam condenser

CONDENSER
Two no. surface condensers are used for condensing the
steam which has worked in the turbine. The coolant for
condensing the steam is circulating water, which is inside
the condenser brass tubes, and steam is outside.

TECHNICAL DATA OF EACH CONDENSER:

Cooling area
No. of brass tubes
Circulating water required for each condenser
Circulating water required for both
condenser2x7500T/Hr.
Allowable difference between
inlet & outlet C.W. water
Vacuum in the condenser

3330 m2
6000
7500T/Hr.
15000T/Hr.
10C Temp.
0.90 Kg/cm2

GENERATOR
The generator is directly coupled with steam turbine at the

speed of 3000 r.p.m.

The hydrogen gas is used to cool the winding of the
generator at constant temp.(water for hydrogen)
The electricity produced by the generator goes to substation through bus bars.
Electricity is generated as per the Faradays Law in
generator.
FARADAYS FIRST LAW : Whenever a conductor cuts
magnetic flux, an emf is induced in that conductor.
FARADAYS SECOND LAW : The magnitude of the
induced emf is equal to the rate of change of flux linkages.

GENERATOR

POWER TRANSFORMER

Advantages and Disadvantages of a Thermal power plant:

Advantages
1.
2.
3.
4.
5.

The fuel used is quite cheap.

Less initial cost as compared to other generating plants.
It can be installed at any place irrespective of the existence of coal. The coal
can be transported to the site of the plant by rail or road.
It require less space as compared to Hydro power plants.
Cost of generation is less than that of diesel power plants.

Disadvantages
1.
2.

It pollutes the atmosphere due to production of large amount of smoke and

fumes.
It is costlier in running cost as compared to Hydro electric plants.