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Project Report
On
“INDUSTRIAL TRAINING AT WANAKBORI T.P.S.’’
Submitted accordance with the industrial Training
Requirement in 7th
semester of BE course in
Mechanical Engineering
Of
Gujarat Technological University
PARUL INSTITUTE OF ENGINEERING AND TECH.
Submitted By: KARAN PARMAR 120370119154
AJAY CHAUHAN 120370119162
ANKUR DABGHAR 120370119157

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Acknowledgement
We are gladly thankful to our H.O.D. and our staff members
who give us a great guidance regarding training and instruct us
the importance of training in mechanical field so we decided to
take training in thermal power plant which is situated at
Wanakbori.
We are especially thankful to respected chief engineer,
Training Centre, Wanakbori thermal power station because we
granted permission to take training in this such wonderful
campus.

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Index
1 Abstract 4
2 Introduction 5
3 Block Diagram of Thermal Power Plant 6
4 Boiler Details 8
5 Turbine Details 13
6 Condenser 14
7 Cooling Tower 15
8 Draught System 17
9 Coal Handling Plant 21
10 Ash Handling System 27
11 Generator Details 29
12 Transformer Details 29
13 DM Plant 30
14 Conclusion 31

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ABSTRACT
The main aim of this training is to study the various types of
mechanical instrument involved in the process of generation of
electrical power.
 We decided to take training to improve practical knowledge and get
benefit their theoretical knowledge.

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INTRODUCTION
 W.T.P.S. is the biggest Thermal Power Plant of GSCEL in Gujarat.
 Wanakbori Thermal Power Plant is a coal-fired power station in
Gujarat, India. It is located on the bank of Mahi River in kheda district.
 There are 7 turbo-generator sets each of 210 MW out of which first 3
units are equipped with Russian Turbines and 4 units are equipped
with German Turbines. Unit no 7 is entirely computerized and well
advanced. All above units are made by BHEL.
Unit No. Installed Capacity Date of
Commissioning
Status
Stage 1 1 210 MW March,1982 Running
Stage 1 2 210 MW January,1983 Running
Stage 1 3 210 MW March,1984 Running
Stage 1 4 210 MW March,1986 Running
Stage 1 5 210 MW September 1986 Running
Stage 1 6 210 MW November 1987 Running
Stage 1 7 210 MW December 1998 Running

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BLOCK DIAGRAM OF POWER PLANT

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FEED WATER & STEAM FLOW DIAGRAM
ENEGRY BALANCE

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Boiler Details:
 Stage I & II : Tangentially Fired, Balance Draft,
Natural Circulation, Radiant Reheat Type
 Stage III : Vertically Suspended Water Tubes,
Radiant Reheat Cycle, Natural Circulation
 Height of Boiler:64 m
 Capacity : 700 Tones / hr
 Feed Water Temp. : 241 ̊C
 Steam Temperature: 540˚C
 Force Draft Fan: 2 Nos
 Induced Draft Fan: 2 Nos
 Primary Air Fan: 2 Nos
 Coal mill: 6 Nos
 Steam Pressures at Boiler Outlets :
[1] SH: 137 Kg / Cm2
[2] RH: 25.8 Kg / Cm2
 Height Of Chimney: Stage 1&2 150 m
Stage 3 220 m

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Economizer:
The feed water from the high pressure heaters enters the economizer
and pick up heat from the flue gases after the low temperature super
heater.
The boiler designer always keep the economizer water outlet
temperature to about 25-35 degrees below the drum saturation
temperature.
Economizer tubes are commonly 38.1×4 mm in OD and made in
vertical sections of continues tubes between inlet and outlet headers
with each sections formed into several horizontal paths connected by
180° bend for proper drainage.
Economizer are generally placed between the last super heater,
reheater and the air preheater.
Chemical and water washing when cleaning the economizer in shut
down time of the station.

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Super heater:
 It is integral part of the boiler and is placed in the path of hot flue
gases from the furnace.
 The heat recovered from the flue gases is used in superheating the
steam before entering into the turbine.
 Its main purpose is to increase temperature of saturated steam
without raising its pressure.
 In WTPS the regenerative super-heater are used.
Air Preheater:
 The purpose of the air preheater is recover the heat from the heat
from the boiler flue gases.
 It increases the thermal efficiency of the boiler by reducing the useful
heat lost in the flue gas.
 Air preheaters are also a requirement for the operation of pulverized-
coal furnaces to dry that fuel.

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Re-heater:
 They are the same as the super-heaters but as their exit temperature
is a little bite less than super heater and their pressure is 20%-25%
less than the super-heater.
 Re-heater tube are commonly 44.5×5 mm in OD
High-pressure feed Heater:
 The high-pressure feed heater is a heat exchanger of the shell and
tube which further heats the feed water before entry to the boiler.
 Bled steam from the turbine is used for heating.
Low pressure feed heater:
 Feed Water from the condensate extraction pumps passes through
five low pressure feed heaters.
 Steam is used to heat the feed water. After the fifth low pressure
heater, the feed water is at 160 c.

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Steam Drum:
 After leaving the economizer, the feed water reaches the steam drum,
which is cylindrical vessel at the top of the boiler.
 From here the water flows by natural circulation through downpipes
into the boiler. Saturated steam collects here ready to go to the SH.
.

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Steam Turbine Details:
 Turbine Consist of multi stage three cylinder with lube oil system, Jack
Oil Pump, bearing lubrication, condenser, LP Heaters, Gland coolers,
HP Heaters, Condensate extraction pumps, Dearators, CW system
and other auxiliaries.
 Type: Three Cylinders Condensing Tandem,
Compound Horizontal Reheat Type.
 Makes: Stage 1-Russian/Lenin Grade Metal Works(LMW) Design
Stage 2-German Craft Work Union (K.W.U) Design
 High Pressure (HP) Turbine(first cylinder)-
Steam Inlet Temperature-535 C
Steam Inlet Pressure 130 Kg/cm2
 Intermediate Pressure(IP) Turbine(Second Cylinder)-
Steam Inlet Temparature-535 C
Steam Inlet Pressure 26 kg/cm2
 Low Pressure (LP) Turbine (Third Cylinder)-It used steam of very low
pressure and temperature.

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Condenser:
 The Surface Condenser are used in WTPS.
 A Surface Condenser is a commonly used term for a water-cooled
shell tube heat exchanger which is installed on the exhaust steam
from a steam turbine.
 The primary purpose of a surface condenser is to condense the
exhaust steam from a steam turbine to obtain maximum efficiency
and also convert in pure water.
 These Condenser are heat exchanger which converts steam from its
gaseous to its liquid state at a pressure below atmospheric pressure.

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Cooling Tower:
 Cooling towers are heat removal devices used to transfer process
waste heat to the atmosphere.
 Cooling towers may either use the evaporation of water to remove
process heat and cool the working fluid. The towers vary in size from
small roof-top units to very large hyperboloid structures.
 Cooling tower is one type of heat exchanger.
 TYPE: Natural Draft Cooling Tower.
 Cooling Tower Heights:
Stage 1& 2: 112 m
Stage 3 & 4:118 m
 By using CEP (Condensate Extraction Pump) cold fluid is again fed into
condenser. And from condenser to cooling tower. Cycle is again
repeated.

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DEAERATOR
 Function of Deaerator is to remove the dissolved gases (oxygen &
carbon Dioxide) in water.
 Presence of oxygen in water react with metal and to form iron oxide.
 To provide net positive suction head(NPSH) for pump, Deaerator
located at sufficient height. When water sucked by pump pressure
does not fall Psat and no flashing of water into vapor ,which protects
BFP from damage & cavitation

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BOILER FEED PUMP.
 Boiler feed pump is a multi-stage pump provided for pumping feed
water to economizer. BFP is biggest auxiliary equipment after boiler
and turbine. It consume about 4 to 5 MW electricity.by using booster
pump we can increase pressure about 35 kg/cm2.
 Then BFP increase the pressure about 150 kg/cm2. And this high
pressure water again fed into the economizer.
DRAUGHT OR DRAFT System.
 The difference between atm pressure and pressure existing in furnace
is termed as draft.
 In a power plant large amounts of air are needed for combustion of
fuel. And huge amount of combustion products (flue gases, ash) have
also removed from boiler so that pressure differential is needed.
Draught is used to define static pressure in furnace, ducts.
Two main function of draught system.
1) Supply required quantity of air for complete combustion of fuel
2) Remove gaseous products of combustion from furnace & throw
through chimney to atmosphere.

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 Mechanical draught is produced by fans. Mechanical draught
equipment much more economical. Two types of fans used in power
plant (1) FD Fan (2) ID Fan
Forced draught:
Function of the FD fan is to supply secondary air to the windbox. Forced
draught fans are installed at inlet to air preheater. They handle cold air
or say atm air. FD Fan forcing air into the furnace and ductwork. Air is
often passed through an air heater; which heats the air going into the
furnace in order to increase the overall efficiency of the boiler.
Dampers are used to control the quantity of air admitted to the
furnace. Forced draught furnaces usually have a positive pressure. Two
FD Fans are used in parallel say A & B. Centrifugal fans with backward-
curved blading type is used in power plant.
TYPE Axial Reaction
CAPASITY 105.3 m3/sec
HEAD 520 mmwc
SPEED 1450 rpm

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Induced draught:
 ID Fans are generally located at the end of ESP(Electro Static
Precipator). induced draught fan (ID fan) which removes flue gases
from the furnace and forces the exhaust gases up to the chimney.
Induced Draught furnaces usually have a slightly negative pressure.
Two ID Fans are used in parallel (say A & B) for better reliability.
Centrifugal fans with forward-curved or flat blading is used in pp.Id fan
creates negative draft inside furnace -5 to -10 mmwc.
.
Balanced draught:
 Balanced draught is obtained through use of both induced and forced
draught.
 This is more common with larger boilers where the flue gases have to
travel a long distance through many boiler passes.
TYPE Axial
CAPASITY 230 m3/sec
HEAD 350 mmwc
SPEED 990 rpm

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 The induced draught fan works in conjunction with the forced draught
fan allowing the furnace pressure to be maintained slightly below
atmospheric.
 Balanced draft pressure is required because furnace were not air tight,
furnace walls were cooled by constant stream of cool air drawn in
slightly negative pressure.
 if allowing these furnace to go positive for even a short time could
result into damage boiler. If boiler operate with excessively negative
pressure than too much air through furnace. Resulting poor burner
and poor efficiency.

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Primary Air Fan:
 Main function of PA fan is to carry coal from pulverizer to furnace and
also heating of coal so that moisture present in coal can be removed
and coal can be easily burnt out in furnace. Discharge of pa fan divided
into two parts first one is cold pa and second one is hot pa after passing
through air preheater which is utilize for transformation of coal from
pulveriser to furnace.
Coal circuit:
 Wanakbori power station is coal based power station.it uses coal as
its fuel. Bituminous coal is used in the Wanakbori power station.
Wanakbori received coal mainly from coal mines situated at Orissa,
Madhya Pradesh, west Bengal, Andhra Pradesh,Chhttisgarh Mines (
south eastern collieries Ltd),WCL(Western Collieries Ltd) & Korea reva
mines.
 To unload received coal rack, Wanakbori thermal power station has
wagon tippler house.there are total 05 no of tipplers which unloads
record 710 nos of wagon in single day.
TYPE Radial Single Suction
CAPASITY 70 m3/sec
HEAD 1210 mmwc
SPEED 1480 rpm

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 Total 5 wagon tipplers installed. 1,2,4 are made by elechon & tippler
5 is hydraulic.
 5 to 7 rack received per day.
 Each railway train carrying 58 wagons is called one rack.each wagon
loads 60 ton of coal which means each rack loads 3600 MT
Approx..Total 18000 MT – 21000 MT of coal is consumed daily to
generate power of 1470 MW.
GRADE Calorific Value(Kcal/kg)
A 6200 & above
B 5601 to 6200
C 4941 to 5600
D 4201 to 4940
E 3361 to 4200
F 2401 to 3360
G 1300 to 2400
 Light diesel oil (LDO) is also used for lighting up the boiler at the time
of start up.
 The steps involved in coal handling are as follows :
1. Coal delivery
2. Unloading
3. Preparation
4. Transfer
5. Outdoor storage
6. Covered storage

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7. In plant handling
8. Weighing and measuring
9. Feeding the coal into furnace.
Coal Delivery
Preparation
Transfer
Outdoor Storage
Unloading
Covered Storage
In plant handling
Furnace
Measuring
Weighting and Measuring

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Coal Delivery.
 The coal from supply points is delivered by orrissa, madya pradesh
, west Bengal, Andhra Pradesh,Chhttisgarh Mines ( south rail ways
to power stations. generally from eastern collieries
Ltd),WCL(Western Collieries Ltd) & korea reva mines.
Belt conveyor.
 It is moving over a pair of end drums roller. At some distance a
supporting roller is provided at the center. The belt is made, up of
rubber & nylon. It is suitable for the transfer of coal over long
distances. The inclination at which coal can be successfully
elevated by belt conveyor is about 20.
 Total length of conveyor belt is around 16 km. width of conveyor
belt is 1500mm, 1400mm &1200mm. belt speed is 3.3-3.6 m/sec.
Stockpiles
 Stockpiles provide surge capacity to various parts of the CPP. ROM coal
is delivered with large variations in production rate of tones per hour
(tph). A ROM stockpile is used to allow the wash plant to be fed coal at
lower, constant rate. A simple stockpile is formed by machinery
dumping coal into a pile, either from dump trucks, pushed into heaps
with bulldozers or from conveyor booms. More controlled stockpiles

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are formed using stackers to form piles along the length of a conveyor,
and reclaimers to retrieve the coal when required for product loading,
etc. Taller and wider stockpiles reduce the land area required to store
a set tonnage of coal. Larger coal stockpiles have a reduced rate of heat
lost, leading to a higher risk of spontaneous combustion.
Stacking
 Travelling, lugging boom stackers that straddle a feed conveyor are
commonly used to create coal stockpiles.
 1 MAMC(mining & Allied Machinery Corporation) stacking capacity
2000 MT/hour.
 2 elechone stacking capacity 1000 MT/hour
Reclaiming
 Tunnel conveyors can be fed by a continuous slot hopper or bunker
beneath the stockpile to reclaim material. Front-end loaders and
bulldozers can be used to push the coal into feeders. Sometimes front-
end loaders are the only means of reclaiming coal from the stockpile.
High-capacity stockpiles are commonly reclaimed using bucket-wheel
reclaimers. two types of reclaimer.

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1.MAMC(Mining & Allied Machinery Corporation)Reclaiming
capacity 1500 MT/hour.
2 .Elechone reclaiming capacity 750 MT/hour.
 Coal size is uneven, so that it is necessary that coal used in plant is in
powder form so better combustion of coal is occurs.
 For this purpose two crusher is used.
1) Primary Crusher.
2) Secondary Crusher.
 Primary crusher: in primary crusher size of coal is max about 125 mm.
capacity of primary crusher is 1100 MT/hour.1A,1B,1C,1D is installed.
 Secondary crusher: in secondary crusher size of coal is max about
30mm.capasity of this crusher is nearly 1100MT/hour.2A, 2B, 2C, 2D is
installed.
 Magnetic separators are provided in plant to remove iron or uneven
impurities in coal. Two magnetic separators are provided.
 Now this coal is go into the bunkers with the help of conveyor belt.
There is total 6 bunkers. But only 4 is in running condition. Hoppers are
used to weigh the quantity of coal.
From bunkers this coal go into the feeders. And from feeders to the mills
or grinders or pulveriser. Total 6 mills are there.in mill we gain coal

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powder. Stockers provided to feeds coal into furnace this coal powder is
lift by PA Fan and sprayed into furnace. Orifice type arrangement is
required to control the quantity of coal into furnace.
 Bowl mill is used in WTPS thermal power plant.
Ash and Flue gases circuit:
 Ash disposal is the major problem in power plant.
 To avoid the atmospheric pollution the fly ash must be removed from
the gaseous products of combustion before they leaves the chimney.
 ID Fan sucks the flue gases from boiler.
 Flue gases contains fly ash and other gases like SOx, NOx. So that it is
necessary to remove fly ash from flue gases
 FLUE GASES PATH:
Boiler furnace
Super heaters
Preheaters
Economizer
Air Preheater

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Elecro Static Precipitator:
 ESP(Electro Static Precipitator) is device that remove particles from
flue gases by using ID Fan charge.
 From air preheater flue gases goes to ESP. this precipitator has plate
blanks A,B,C,D,E,F which are insulated from each other between which
the flue gases are made to pass. Dust particles are ionized and
attracted by charged electrode are maintained at 60KV.hammering is
done to the plates so that fly ash comes down and collect at the bottom
the fly ash is dry form is used in jp cement manufacture.
 Silo is also provided in plant.
ESP
Chimney

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Generator Details:
 Type: THW - 210 – 2B (Water & Hydrogen Cooled Turbo Generator)
 Rated Capacity: 210 MW, 247 MVA
 Power Factor: 0.85 Lag
 Stator: 15.75 Volts, 9050 A
 Rotor: 310 V DC, 2600 A
 Excitation System: Static
 Type of Cooling: Water, Hydrogen
 Hydrogen Pressure: 3.5 Kg / Cm2
Transformers Details:-
 Generator Transformer:
 Stage I: 250 MVA, 15.75 / 220KV
Stage II: 250 MVA, 15.75/400KV
 Interconnection Transformer: 500 MVA (167 x 4, 3+1 St by), 220 / 400
KV Station Transformers: 25 MVA, 220 / 07 KV Unit Auxiliary
 Transformers: 15 MVA, 15.75 / 07 KV Unit Service Transformers: 07
KV / 433 Volts Station Service Transformers: 02 MVA, 07 KV / 433
Volts

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Demineralization(DM) Plant:
 Demineralization is the process of removing mineral salts from water
by using the action process.
 Basic Processes:- 1.Distiallation
2. Membrane Filtration
3. Deionizing
4. Degasser
 In the Context of water purification, ion exchange resin. The impurity
ions are taken up by the resin.
 The following ions are widely found in raw water
1. Cations :-Calcium (Ca2+), Magnesium (Mg2+), Sodium (Na+)
Potassium (K+)
2.Anions:-Chlorine(Clˉ),Bicarbonate(HCO3ˉ),Nitrate(NO3ˉ)

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Conclusion:
After this training at the Wanakbori Thermal Power Station we can
visualized the complex study of power generation using coal as a fuel,
which will help us a lot in future in many field & we can understand the
function of each component in thermal power station, their importance,
their arrangement & precautions that to be used for the safety in the
plant.
We only say that we really enjoyed us training over here and we again
want to thank all my faculties, staff of Wanakbori Thermal Power Station
to give us this great pleasure of the training.
At last we conclude that we got good knowledge and great experience
at the WTPS.