GSECL TPS SIKKA

GSECL THERMAL POWER STATION, SIKKA
INDUSTRIAL TRAINING REPORT
AT
THERMAL POWER STATION, SIKKA
SUBMITTED IN PARTIAL FULFILLMENT OF THE
REQUIREMENT FOR THE AWARD OF DEGREE OF
BACHELOR OF ENGINEERING
IN
ELECTRICAL ENGINEERING
SUBMITTED BY:
1. MAKWANA MUKUNDRAY J. 150933109054
2. BAROT GAUTAM S. 150933109006
ARRDEKTA INSTITUTE OF TECHNOLOGY, KHEDBRAHMA
GUJARAT TECHNOLOGIACL UNIVERSITY

Index
TITLE
 Declaration
 Acknowledgment
 Certificate
 Preface
1. Introduction
2. Purpose of Training
3. Types of thermal Energy
4. Efficiency of plant
5. Thermal Power plant
 Components
 Working principle
6. Control Room
7. DM Water plant
8. Switch yard
9. Conclusion

DECLERATION
This report is based on the industrial training I have undergone in the
premises of GSECL Thermal Power Station. A unit of Gujarat State Electricity
Corporation Ltd. (GSECL), SIKKA from 28 May, 2018 to 08 June, 2018. I
obtained the knowledge of Turbines and Generators through the selfless efforts
of the Employee arranged to me by the Company administration. The training was
based on study of Electricity production. The experience of the training was good
and I learned lots of things. I was successfully able to complete the training.
1. Makwana Mukundray J. ___________________
2. Barot Gautam S. ___________________

ACKNOWLEDGEMENT
I would like to thank the entire GSECL Thermal Power Station, Sikka.
Who has provided me this seasonal training. I am thankful to Chief Engineer of
TPS Sikka. for their benevolent guidance and kind cooperation throughout my
training along with completing this project report and provided me the various
knowledge about their stations.
I also thanks to the workers of their respective stations, who were always
ready to clarify my doubts and helped me to increase my knowledge by illustrating
me to the finer points.
I wish to express my deep gratitude to all the concerned persons, whose
enthusiasing support and co-ordination have given me the success to complete my
training in the organization.
I hope that my report will reflect my technical knowledge and innovativeness,
which I gained at GSECL Thermal Power Station, Sikka.

preface
A student gets theoretical knowledge from classroom and gets practical
knowledge from industrial training. When these two aspects of theoretical
knowledge and practical experience together then a student is full equipped to
secure his best.
In conducting the project study in an industry, students get exposed and have
knowledge of real situation in the work field and gains experience from them.
The fact that thermal energy is the major source of power generation itself
shows the importance of thermal power generation in India more than 55% to 60%
of electricity produce by steam plant in India.

Certificate
This is to certify that the Project Reports, submitted along with the project
entitled “Industrial Training at GSECL Thermal Power Station, Sikka” has
been carried out by Makwana Mukundray J. (150933109054) under my
guidance in partial fulfillment for the degree of Bachelor of Engineering in
Electrical Final year of Gujarat Technological University, Ahmadabad during the
academic year 2017-18. These students have successfully completed Project
activity under my guidance.
____________________ ____________________
Chief Engineer of GSECL HOD Electrical

Certificate
This is to certify that the Project Reports, submitted along with the project
entitled “Industrial Training at GSECL Thermal Power Station, Sikka” has
been carried out by Barot Gautam S. (150933109006) under my guidance in
partial fulfillment for the degree of Bachelor of Engineering in Electrical Final
year of Gujarat Technological University, Ahmadabad during the academic year
2017-18. These students have successfully completed Project activity under my
guidance.
____________________ ____________________
Chief Engineer of GSECL HOD Electrical

Introduction
The Sikka Thermal Power Station is located near Jamnagar. It is Coal Based
Power Station. There are two units of 250 MW each with a total installed capacity
of 740 MW. All the above units are of BHEL make.
In a coal based power plant coal is transported from coal mines to the power
plant by railway in wagons or in a merry-go-round system. Coal is unloaded from
the wagons to a moving underground conveyor belt. This coal from the mines is of
no uniform size. So it is taken to the Crusher house and crushed to a size of 20mm.
From the crusher house the coal is either stored in dead storage( generally 40 days
coal supply) which serves as coal supply in case of coal supply bottleneck or to the
live storage(8 hours coal supply) in the raw coal bunker in the boiler house. Raw
coal from the raw coal bunker is supplied to the Coal Mills by a Raw Coal Feeder.
The Coal Mills or pulverize pulverizes the coal to 200 mesh size. The powdered
coal from the coal mills is carried to the boiler in coal pipes by high pressure hot
air. The pulverized coal air mixture is burnt in the boiler in the combustion zone.
Generally in modern boilers tangential firing system is used i.e. the coal
nozzles/guns form tangent to a circle. The temperature in fire ball is of the order of
1300 degree C. The boiler is a water tube boiler hanging from the top. Water is
converted to steam in the boiler and steam is separated from water in the boiler
Drum. The saturated steam from the boiler drum is taken to the Low Temperature
Super heater, Platen Super heater and Final Super heater respectively for
superheating. The superheated steam from the final super heater is taken to the
High Pressure Steam Turbine (HPT). In the HPT the steam pressure is utilized to
rotate the turbine and the resultant is rotational energy. From the HPT the out
coming steam is taken to the Re-heater in the boiler to increase its temperature as
the steam becomes wet at the HPT outlet. After reheating this steam is taken to the
Intermediate Pressure Turbine (IPT) and then to the Low Pressure Turbine (LPT).
The outlet of the LPT is sent to the condenser for condensing back to water by a
cooling water system. This condensed water is collected in the Hot well and is
again sent to the boiler in a closed cycle. The rotational energy imparted to the
turbine by high pressure steam is converted to electrical energy in the Generator.
A thermal power station is a power station in which heat energy is
converted to electric power. In most of the places in the world the turbine is steam-
driven. Water is heated, turns into steam and spins a steam turbine which drives
an electrical generator. After it passes through the turbine, the steam

is condensed in a condenser and recycled to where it was heated; this is known as
a Rankin cycle. The greatest variation in the design of thermal power stations is
due to the different heat sources; fossil fuel dominates here, although nuclear heat
energy and solar heat energy are also used. Some prefer to use the term energy
center because such facilities convert forms of heat energy into electrical energy.
Certain thermal power stations also are designed to produce heat energy for
industrial purposes, or district heating, or desalination of water, in addition to
generating electrical power.

Purpose of Training
Engineering means the application of science. The beauty of science lies in its
practical applications. Practical knowledge of the working of theory studied in
theoretical season at college lectures is as much necessary as the theoretical
knowledge. Training is the processed of planed programs and procedure
undertaken for the improvement of knowledge & performance in terms of his
attitude, skills, knowledge and behavior of students.
So taking into account improvement of practical application of knowledge, we
decided to undergo training at Sikka Thermal Power Station to have an insight into
electricity generation process.
The fact of STPS is power plant in Gujarat we were able to understand the process
of electricity generation fully right from the stage collecting coal to the distribution
of generated electricity to the people.

Types of Thermal Energy
Almost all coal, nuclear, geothermal, solar thermal electric, and waste
incineration plants, as well as many natural gas power plants are thermal. Natural
gas is frequently combusted in gas turbines as well as boilers. The waste heat from
a gas turbine can be used to raise steam, in a combined cycle plant that improves
overall efficiency. Power plants burning coal, fuel oil, or natural gas are often
called fossil-fuel power plants. Some biomass-fueled thermal power plants have
appeared also. Non-nuclear thermal power plants, particularly fossil-fueled plants,
which do not use Co-generation are sometimes referred to as conventional power
plants.

Efficiency of plant
A huge amount of heat is lost in various stages of the plant. Major part of heat
is lost in the condenser. That is why the efficiency of thermal plants is quite low.
1. Thermal Efficiency:
The ratio of 'heat equivalent of mechanical energy transmitted to the
turbine shaft' to the 'heat of coal combustion' is called as thermal
efficiency.
THERAML EFFICIENY =
Thermal efficiency of modern thermal power stations is about 30%. It
means, if 100 calories of heat are produced by coal combustion, the
mechanical energy equivalent of 30 calories will be available at the
turbine shaft.
2. Overall Efficiency:
The ratio of 'heat equivalent of electrical output' to the 'heat of coal
combustion' is called as overall efficiency.
OVERALL EFFICIENCY=
The overall efficiency of a thermal plant is about 29% (slightly less
than the thermal efficiency).

Thermal Power Plant
A thermal power station is known as power plant in which the prime mover
is steam drive. Water is made to enter into the system and then heated, later which
turns into the steam. The steam spins in a steam turbine which efforts an electrical
generates.

The Basic Components of the Thermal Power
Station are
1. Coal yard
2. Coal crusher
3. Bunker
4. Coal mill
5. Boiler
6. Steam turbine
7. Condenser
8. Generator
9. Cooling tower
10.Forced draught fans
11.Induced draught fans
12.Primary air fans
13.Electrostatic precipitator (ESP)
14.Chimney

These are the main components in the thermal power plant
1. COAL YARD
Fig. Coal Yard
 In the coal yard the wagon full of coal is emptied automatically.
 In this first the wagon is sprayed of water.
 Then the wagon is clamped by horizontal and vertical clamp.
 Then the DC motors rotates the bridge and the coal is emptied from the
wagon.
 Then the bridge came into original position.

2. COAL CRUSHER
 The coal crusher is used to crush the coal.
 From the floor the rack pull out the coal.
 In the crusher there is one mill which crack the large stone of coal.
 There magnet is used to pull out the metal partials present in the coal.
 From the crusher is stored in the bunker or either on ground.
 The continues water is sprayed on the coal due to the property of coal
burn in the air so the water spray is required.
 The JCB is used to supply coal to bunker from the grond storage.
3. BUNKER
Fig. Bunker
 The bunker is one type of storage.
 The belt is used to pull out the coal from crusher.
 From the bunker the coal enters into the feeder.
 From the feeder the coal enter into the coal mill.

4. COAL MILL
Fig. Coal Mill
 The coal needed to be fine particles to burn efficiently.
 Here the bowl type coil mill used.
 From the feeder the centrally located pipe feed the coal into mill.
 The roller is used to crush the coal.
 The PA Fan blows the air from the bottom and fly out the crushed coal
into boiler from the mill.
 The 4 pipe used to outlet.
 The coal is prevented to enter into the bearing so seal pump is also used.
 DATA
 No. of coal mill : 6 Nos.
 Maximum capacity : 45 TPH
 Mill Speed : 26 RPM
 Mill type : Medium speed vertical grinder roller

5. BOILER
Fig. Boiler
 Now that pulverized coal is put in boiler furnace.
 Boiler is enclosed vessel in which water is heated and circulated until the
water is turned into steam is required pressure.
 Coal is burned inside the combustion are nothing but gases.
 These gases which are at high temperature vaporize the water inside the
boiler to steam.

 This steam at high pressure and temperature is used directly as a heating
medium, or as the working fluid in a prime mover to convert thermal energy
to mechanical work, which in turn may converted to electrical energy.
 BOILER COMPONENTS:
 Water wall
 Separator
 Economizer
 Super heater
 Re-heater
6. STEAM TURBINE
Fig. Turbine

 Turbine is machine in which a shaft is rotated steadily by impact or reaction
of current or steam of working substance (steam, water, gases etc. ) upon
blades of a wheel.
 It convert the potential energy or kinetic energy of working substance into
mechanical power by virtue of dynamic action of working substance. When
the working substance is steam it is called steam turbine.
 DESCRIPTION OF STEAM TURBINE:
 HP turbine
 IP turbine
 LP turbine
7. CONDENCER
Fig. Condenser

 Steam after rotating steam turbine comes to condenser. Condenser refers
here to the shell and tube heat exchanger (or surface condenser) installed at
the outlet of every steam turbine in thermal power stations of utility
companies generally. These condensers are heat exchangers which convert
steam from its gaseous to its liquid state, also known as phase transition.
 The purpose is to condense the outlet steam from steam turbine to obtain
maximum efficiency and also to get the condensed steam in the form of pure
water, otherwise known as condensate, back to steam generator pr boiler as
boiler feed water.
8. GENERATOR
 An alternator is an electro mechanical device that converts mechanical
energy to alternating current electrical energy.
 In principle, any AC generator can be called an alternator, but usually the
word refers to small rotating machine driven by automotive and other
internal combustion engines.
 Generator is connected with the all HP, IP and LP turbine so when the
turbines rotates by the pressure of the steam the generator also rotate and due
to magnetic field it generate electricity.
 DATA DESCRIPTION:
 Kilo watt : 250kw
 Power factor : 0.85 Lag
 KVA : 291400
 RPM : 3000

9. COOLING TOWER
Fig. Cooling Tower
 The condensate formed in the condenser after condensation is initially at
high temperature. This hot water is passed to cooling towers.
 Water acting as the heat transfer fluid, gives up heat to atmospheric air, and
thus cooled, is recalculated through the system, affording economical
operation of the process.
 Inlet water temperature : 60ºC
 Inlet water temperature : 30ºC
10. FORCRD DRAUGHT FANS
 Air drawn from atmosphere is forced into the furnace into the furnace, at a
pressure higher than the outside atmosphere, by big centrifugal fan or fans to
create turbulence and to provide adequate oxygen for combustion.
 Forced draught fans are used to provide a positive pressure to a system.

11. INDUCED DRAUGHT FANS
 Instead of drawing atmospheric air and pushing through furnace, a
centrifugal fan can be deployed to draw out the air from the furnace and
throw out through chimney, Induced draught fans are used to provide a
negative pressure or vacuum in a slack or system
 The system is called Induced Draught system and the fan deployed for this
purpose is known as induced Draught Fan.
12. PRIMARY AIR FAN
 These are the large high pressure fans which supply the air needed to dry
and transport coal either directly from the coal mills to the furnace or to the
intermediate bunker.
 These fans may locate before or after the milling equipment. The most
common application is cold primary air fans, hot primary air fans.
13. ELECTROSTATIC PRECIPITATOR (ESP)
 It is a device which removes dust or other finely divided particles from flue
gases by charging the particles inductively with an electric field, then
attracting them to highly charged collector plates. Also known as
precipitator.
 The process is depend on two steps. In the first step the suspension passes
through an electric discharge (corona discharge) area where ionization of the
gas occurs. The ions produced collide with the suspended particles and
confer on them an electric charge.
 The charge particles drift toward an electrode of opposite sign and are
deposited on the electrode where their electric charge is neutralized. The
phenomenon would be more correctly designated as electrode position from
the gas phase.

14. CHIMNEY
Fig. Chimney
 A chimney is a system for ventilating hot flue gases or smoke from a boiler,
stove, furnace or fireplace to the outside atmosphere.
 The space inside a chimney is called a flue. Chimney may be found in
building, steam locomotive and ships.

Working Principle of Thermal Power Plant:
Water is used as the working fluid in the thermal power plant. We can see
coal based and nuclear power plants in this category. From the working of the
power plant energy, later from the fuel gets transferred into the form of electricity.
With the help of high pressure and high steams a steam turbine in a thermal power
plant is rotates, the rotation must be transfer to the generator to produce power.
When turbine blades are rotated with the high pressure and high temperature
at that case the steam loses its energy. So it results in the low pressure and low
temperature at the outlet of the turbine. Steam must be expanded up to the point
where it reaches the saturation point. So from the steam, there is no heat addition
or removal that takes place. Entropy of the steam remains same. So we can notice
the change in the pressure and volume and temperature along with the entropy
diagrams. If the condition comes to the low pressure and low temperature steam
back to the original state, from that we can produce continuous electricity.
To compress the gaseous state liquids at that case large amount of energy is
required. So before the compression we need to convert the fluids into liquid state.
For this purpose condenser is required and heat is rejected to the surroundings and
converts the steam into liquid state. During this process the temperature and
volume of the fluid changes take place hardly, so it turns into liquid state. And the
fluid turns to the original state. To bring the fluid to the original state external heat
is added. To the heat exchanger heat is added which is called as boiler. Then the
pressure of the fluid must remain same. In heat exchanger tubes it expands freely.
Due to increase in temperature the liquid state is transformed into the vapor state
and the temperature remains same. So know we complete the thermodynamic cycle
in the thermal power plant. It is known as Rankin cycle. By repeating the cycle we
can produce the power continuously.
With the help of boiler furnace heat is added to the boiler. Then the fuel must
reacts with the air and produces heat. The fuel must be either nuclear or coal. In
this process if we use coal as a fuel we can observe lot of pollutants before ejects in
to the air clean or removed the particles and send into surroundings. The process is
done in various steps. By using the electro static precipitator the ash particles are
removed. So with the help of the stack clean exhaust must be send outside.

DM Water Plant
Demineralization is the process of removing minerals salts from the water by using
the ion exchange process.
Demineralised water is completely free of dissolved minerals as a result of one of
the following process:
Demineralization water also known as Deionized water, water that has had its
mineral ions removed. Mineral ions such as cations of sodium, calcium, ions,
copper, etc. and anions such as chloride, sulphate, nitrate, etc. are common ions
present in water. Deionization is a physical process which uses specially
manufactured ion exchange resins which provides ion exchange site for the
replacement of the mineral salts in water with water forming H+ and OH+ ions.
Because the majority of water impurities are dissolved salts, deionization produces
a high purity water that is a generally similar to distilled water, and this process is
quick and without scale buildup. De-mineralization technology is the proven
process for treatment of water. A DM water system produces mineral free water by
operating on the principle of ion exchange, Degasification, and polishing.
Demineralization water system finds wide application in the field of steam, power,
process and cooling.

Control Room
In a power station control room acts as the never center.the following controls are
located in a control room.
i. Circuit breaker
ii. Load and voltage adjustment
iii. Transformer tap changing
iv. Emergengy tripping of turbine
v. The instrument can indicate load, voltage, frequency, power factor,
Winding temperature and water levels in the case of hydrostation and
so on.
vi. Synchronizing eqipments
vii. Voltage regulators
viii. Relays
ix. Integrating meters and other appliances
The control room should be well arranged as follows:
i. Control room should be clean and comfortable.
ii. Should be ventilated and well lighted
iii. Should be free from draughts.
iv. There should be no glare.
v. The instruments should have clear scales properly calibrated.
vi. All the appratus and circuit should be labelled so that they clearly
visible.

Fig. Control Room
 Equipment / instruments used in control room
a. Indicating instruments
b. Recorders
c. Controllers
d. Relay
e. Annouciator

Switchyard
The switchyard is a type of step up substation which transmits the power at
high voltage to different centers through heavy buses and large insulators. A
substation comprise of the various equipments:
 Transformer
 Isolators
 Circuit breaker
 Lightning arrester
 Wave trap
 Current transformer (CT)
 Potential transformer (PT)
 Bus bar and clamp fitting
 Supporting structure for
hanging buses
 Control relay panel
 Control room
 Fire fighting equipments
 Power cable and control cable
 Interpolate current transformer
Fig. Switch Yard

Characteristics of steam power plant:
 It gives high efficiency
 Cost is low
 Water requirement is reduced
 Environmental impact like air pollution is reduced
 Higher availability and reliability
 Ability to burn coal mainly high ash content
Advantages
 They can respond to rapidly changing loads without difficulty
 A portion of the steam generated can be used as a process steam in
different industries
 Steam engines and turbines can work under 25 % of overload
continuously
 Fuel used is cheaper
 Cheaper in production cost in comparison with that of diesel power
stations
Disadvantages
 Maintenance and operating costs are high
 Long time required for erection and putting into action
 A large quantity of water is required
 Great difficulty experienced in coal handling
 Presence of troubles due to smoke and heat in the plant
 Unavailability of good quality coal
 Maximum of heat energy lost
 Problem of ash removing

Conclusion
 The first phase of practical training has proved to be quite fruitful. It
provided an opportunity for encounter with such hardworking engineers.
 The architecture of the power plant the way various units are linked and they
way working of whole plant is controlled make the student realize that
engineering is not just learning the structured description and working of
various machines, but the greater part is of planning proper management.
 It also provide an opportunities to learn low technology used at proper place
and time can cave a lot of labor but there are few factors require special
attention.
 However training is proved to be quite fruitful. It has allowed an opportunity
to get an exposure of the practical implementation to theoretical
fundamentals.

GSECL TPS SIKKA

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