WINTER INTERNSHIP REPORT DEC16-JAN17 (14DAYS)

AT JPCL JAMSHORO, SINDH

SUBMITED BY : MEER MUHAMMAD (16ME131)

DEPARTMENT OF MECHANICAL ENGINEERING, MUET JAMSHORO

PROGRAM : B.E MECHANICAL ENGINEERING (2ND YEAR)

SUBMITED TO : SIR RIZWAN ARAIN

Acknowledgement

It was a unique experience to be in thermal power station Jamshoroand 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. I would like to thank all the people that worked at tps Jamshoro specially thanks to Sir Rizwan Arian with their patience and openness they created an enjoyable working environment. Furthermore I want to thank all the Engineers and workers , By whom we learned the fieldwork.

Introduction

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) 5 Km North-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 of four units having total rated capacity of 880 MW. Unit No.1 250 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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Mechanical Components :

(1)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/hSteam max temp=540 CHeating surface of SH and economizer=17533Furnace type=natural circulation pressurized furnace.

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(2) Steam turbine:

Steam Turbine is the heart of a Thermal Power Station. In order to turn theSteam Turbine, we must supply high temperature and high pressure steam atthe inlet of the turbine. As the turbine absorbs energy from the steam, itstemperature and pressure drops toward the outlet. The rotor blades of steamturbine are having Aerofoil shape for converting maximum amount of thermalenergy of steam into mechanical energy of turbine rotor. High Capacity PowerPlants use different stages of Steam Turbine as:a) High Pressure (H.P) Turbineb) Intermediate Pressure (I.P) Turbinec) Low Pressure (L.P) TurbineThe steam first enters at the inlet of HP Turbine with a temperature andpressure of 540oC and 132 kg/cm2 respectively. At the outlet of HP Turbine,the temperature drops to 350oC. For increasing the efficiency of Thermalpower plant, we add more heat to the steam through Re-Heaters situated inBoiler. After Re heating, 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 outlet of LP Turbine, the temperature and pressure of steam has dropped to 0.2 kg/cm2 and 50oC 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.

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Total 8 Extractions are drawn from Steam Turbine. 2 from HP, 4 from IP, and2 from LP steam Turbine. These are drawn for pre-heating purposes.(3) Condenser :

The low pressure and low temperature steam from the outlet 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 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 (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 tothe LP (Low Pressure) Heaters through Condensate Pump. 4 LP heaters areused 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 feedwater to steam-generating boilers. We take 1-Extraction IP steam Turbine for the processing of Deaerator. This whole cycle is Condensation Cycle

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(4)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 1 is centrifugal type and with power of 3800 kw, capacity of 485ton/hr and 1485rpm speed. Cooling system for pump such as lubrication or water is also available to cool bearings and rotating parts.

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(5)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.

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(6)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 all other units contain both ID and FD fans (balanced draught).

(7) Flue Gas Stack (Chimney)

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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 them are 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 throughFlue Stack.

Conclusion

It was such a nice 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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Overall Thermal Power Plant Layout

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