All About Thermal power Plant

1. In the name of Allah, the
Most Gracious, the Most
Merciful.

2. PRESENTATION
Thermal Power Plant
Muzafergarh

3. GC UNIVERSITY FAISALABAD
LAYYAH CAMPUS
DEPARTMENT OF MECHANICAL ENGINEERING TECHNOLOGY
NORTHERN POWER GENERATION COMPANY LIMITED
GENCO III
THERMAL POWER STATION MUZAFFARGARH

4. PRESENTED BY:
Shahzaib Hussain
13-MT-26

5. TABLE OF CONTENT
 HISTORY OF POWER SECTOR
 HISTORY OF PAKISTAN POWER SECTOR
 ENERGY SECTOR IN PAKISTAN
 ENERGY RESOURCES
 THERMAL POWER STATION MUZAFERGARH
 SOURCE OF ENERGY
 SLECTION OF SITE
 THERMAL POWER PLANT
 THERMAL POWER PLANT & RANKINE CYCLE
 THERMAL POWER PLANT LAYOUT
 WATER CYCLE

6.  BOILER OPERATION AND ITS COMPONENTS
 TURBINE OPERATION
 GENERATOR
 OTHER COMPONENTS OF THERMAL POWER STATION
 IMPORTANT POINTS
 ADVANTAGES & DISADVANTAGES
 SUGGESTIONS FOR IMPROVEMENT
 FEEDBACK

7. HISTORY OF POWER SECTOR
For thousands of years, people all over the world have been fascinated by lightning. Some
people must have wondered how to put that kind of power to practical use. But it wasn't until
the 18th century that the path to the everyday use of electrical power began to take shape.
Maybe you have heard about the famous kite experiment by American Founding Father and
inventor Benjamin Franklin. In 1752, to prove that lightning was electrical, he flew a kite
during a thunderstorm.
He tied a metal key onto the string and, as he suspected it would, electricity from the storm
clouds flowed down the string, which was wet, and he received an electrical shock. Franklin
was extremely lucky not to have been seriously hurt during this experiment, but he was excited
to have proved his idea.

8. Electricity is a form of energy and it occurs in nature, so it was not “invented.” As to who
discovered it, many misconceptions abound. Some give credit to Benjamin Franklin for
discovering electricity, but his experiments only helped establish the connection between
lightning and electricity, nothing more
Throughout the next hundred years, many inventors and scientists tried to find a way to use
electrical power to make light. In 1879, the American inventor Thomas Edison was finally
able to produce a reliable, long-lasting electric light bulb in his laboratory. By the end of
the 1880s, small electrical stations based on Edison's designs were in a number of U.S.
cities. But each station was able to power only a few city blocks.
Although the majority of people living in larger towns and cities had electricity by 1930, only
10 percent of Americans who lived on farms and in rural areas had electric power. At this
time, electric companies were all privately owned and run to make money.

9. HISTORY OF PAKISTAN POWER SECTOR
At the time of independence, Pakistan inherited 60MW of power generation capability for a
population of 31.5 million, yielding 4.5 units per capita consumption. Twelve years later, when
WAPDA was created in 1959, the generation capacity had increased to 119 MW. By that time
country had entered the phase of development, which required a dependable and solid
infrastructure, electricity being its most significant part. The task of power development was
undertaken by WAPDA for executing a number of hydel and thermal generation projects, a
matching transmission network and a distribution system, which could sustain the load of rapidly
increasing demand of electricity.

10. The effects of WAPDA's professional approach to find the solution to multifarious
problems did not take long to show. After first five years of its operation by 1964-65, the
electricity generation capability raise to 636 MW from 119 in 1959, and power
generation to about 2,500 MKWH from 781 MKWH. Number of consumers in 1959 to
688 thousand in 1965. As many as 609 villages had electricity supplied to them by 1959,
increasing to 1882 in 1965. The rapid progress witnessed a new life to the social,
technical and economic structures of the country, mechanized agriculture started,
industrialization picked up and general living standards improved.
The task of accelerating the pace of power development picked up speed and by 1970, in
another five years the generating capability raise from 636 MW to 1331 MW with
installation of a number of thermal and hydel power units. In the year 1980 the system
capacity touched 3000 MW which rapidly raise to over 7000 MW in 1990-91.
Electricity in Pakistan is generated, transmitted, distributed, and retail supplied by two
vertically integrated public sector utilities: Water and Power Development
Authority (WAPDA) for all of Pakistan.

11. (except Karachi), and the Karachi Electric (K-Electric) for the city of Karachi and its
surrounding areas. There are around 42 independent power producers (IPPs) that contribute
significantly in electricity generation in Pakistan.
Electricity generation has increased by 20.18% in August 2017 as a result of Government of
Pakistan (GOP) efforts and China–Pakistan Economic Corridor (CPEC). The country has
begun diversifying its energy producing capacity by investing in coal, nuclear energy, solar
energy and wind energy to help offset the energy shortage while larger projects greater than
1000 MW such as the Diamer-Bhasha Dam, Kohala Hydropower Project, Pakistan Port Qasim
Power Project, Sahiwal Coal Power Project, Thar Engro Coal Power Project, Hub Coal Power
Project and new nuclear plants are now under construction or planned.

12. ENERGY SECTOR IN PAKISTAN
o Electricity – total installed capacity: 23,928 MW (2016)
o Thermal – 14,635 MW – 64.2% of total
o Hydro – 6,611 MW – 29% of total
o Nuclear – 1,322 MW – 5.8% of total
o Average demand-18,000 MW
o Shortfall-between 5,000 MW and 6,000 MW
o There are four major power producers in country: WAPDA, K-
Electric, IPPs and Pakistan Atomic Energy Commission (PAEC).

13.  Conventional
 Hydro
 Nuclear
 Thermal
 Non Conventional
 Wind Power
 Solar Power
 Geothermal
 Tidal Waves
 Biomass
ENERGY RESOURCES

14. TPS MUZAFERGARH
Thermal Power Station Pakistan is located at Muzafargarh, Punjab, Pakistan. This
infrastructure is of TYPE Gas Power Plant & Furnace Oil with a design capacity of
1350 MW. It has 6 unit(s). The first unit was commissioned in 1993 and the last in
1995. It is operated by Pakistan Electric Power Company (PEPCO). These units made
by RUSIA & CHINA.
Thermal Power station Muzafergarh is a vital & major power plant in Pakistan
connected with National Grid System. Thermal Power station Muzafergarh is situated
an approximate 2.5 km from Muzafergarh city.

15. INSTALLED CAPACITY
Thermal power station was constructed in 02 phases having
total capacity of 1350 MW.
o Three Russian Units of 210 MW each
o Two Chinese Units of 200 MW each
o One Chinese unit of 320 MW
SOURCE OF ENERGY
Dual fuel combustion provision (Gas & Furnace Oil) has been made for all the Machines
in TPS Muzafergarh. Fuel is transported through Railway wagons & Tank Lorries.
Primary Source of energy for Thermal power plants are
o Coal
o Natural Gas
o Furnace oil

16. SLECTION OF SITE
 Availability of cheap land
 Availability of water
 Availability of fuel
 Transport facilities
 Nature of Land
 Man power
 Distance from populated area
 Ash disposal facility
 Possibility of future expansion

17. THERMAL POWER PLANT
A thermal power station is a power plant 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.
Use the heat energy to boil water, producing steams.
The steam turbine spins and then drives the electric generator.
Condense the steam into water for reusing.
Repeat the cycle. This cycle is known as the Rankine cycle

19. THERMAL POWER PLANT & RANKINE CYCLE
 Process 1-2: The working fluid is pumped from low to high pressure. As the fluid is a
liquid at this stage, the pump requires little input energy.
 Process 2-3: The high pressure liquid enters a boiler where it is heated at constant
pressure by an external heat source to become a dry saturated vapor. The input energy
required can be easily calculated graphically, using an enthalpy-entropy chart (aka h-s
chart ).
 Process 3-4: The dry saturated vapor expands through a turbine, generating power.
This decreases the temperature and pressure of the vapor, and some condensation may
occur. The output in this process can be easily calculated using the chart or tables noted
above.
 Process 4-1: The wet vapor then enters a condenser where it is condensed at a constant
pressure to become a saturated liquid.

22. THERMAL POWER PLANT LAYOUT

24. Raw
Water
Purified
DM
water
For
cooling
purpose
Steam
Conden
ser
WATER CYCLE Reservoir
Water Clarification
DM Plant
(Demineralized Plant)
Chlorification
&
Filtration
Various Equipment
Cooling Water
Auxiliary cooling
Water (ACW)
DMCW Demineralized
cooling Water
Boiler
Steam
Various Equipment
Cooling Tower
CT
CWP
Condenser
Steam
water
Cool water
Hot water
DMCWP
CWPCWP
water
Hot WellDearator
25D  35D
25D  20D
PHE

25. BOILER OPERATION & ITS COMPONENTS
A boiler is defined as "a closed pressure vessel having minimum capacity of 22.70 liters in which water or
other liquid is heated, steam or vapor is generated steam is superheated. Steam can be generated as per
desired pressure & temperature.

27. BOILER PERAMETERS

28.  WATERTUBE BOILER
A water tube boiler (also spelled water-tube and water
tube) is a type of boiler in which water circulates
in tubes heated externally by the fire. Fuel is burned inside
the furnace, creating hot gas which heats water in the
steam-generating tubes.

29.  FIRETUBE BOILER
A fire-tube boiler is a type of boiler in which hot gases
from a fire pass through one or (many) more tubes running
through a sealed container of water. The heat of the gases
is transferred through the walls of the tubes by thermal
conduction, heating the water and ultimately creating
steam.

30.  SUPER HEATER
A super heater is a device used to convert saturated steam or wet steam into superheated
steam or dry steam. Super heaters are used in steam turbines for electricity generation.

31.  ECONOMIZER
A common application of economizers in steam power plants is to capture the
waste heat from boiler stack gases (flue gas) and transfer it to the boiler feed
water. This raises the temperature of the boiler feed water, lowering the needed
energy input, in turn reducing the firing rates needed for the rated boiler output.

32.  AIR PRE-HEATER
An air preheater (APH) is a general term used to describe any device designed to
heat air before another process (for example, combustion in a boiler) with the primary objective
of increasing the thermal efficiency of the process

33.  ID & FD FAN
Induced Draft: - A fan is used to extract the air from boiler post combustion via
(Electrostatic Precipitator if present) to exhaust through the chimney. This is called ID
fan.
Forced draft: - A fan is used to force air into the boiler to provide more air for
combustion. This is called FD fan

34.  SOOT BLOWER
A soot blower is a device for removing the soot that is deposited on the furnace tubes of a
boiler during combustion.

35. BOILER MOUNTINGS
The boiler mountings are used for safe & efficient operation of boiler,
these are placed in outside of the boiler.
 Safety Valve
 Pressure Gauge
 Water level Gauge Glass
 Startup vent
 Air vent
 Main Hole

36. TURBINE
A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to do
mechanical work on a rotating output shaft.

37. Steam enters from the left through the pipe at the top, arriving in the very middle of the turbine and just
above it. Then it simultaneously flows in both directions (to the left and the right) through the low-pressure
reaction turbine, which drives the electricity generator on the right
WORKING PRINCIPLE

38. Condenser
HPT IPT LPT
RH
Steam
Super
Heater
Generator
Steam
Shaft

39. TYPES OF TURBINE
o Rotor
o Blades (fixed and moving)
o Bearings (thrust and journal)
o Turbine casing
o Valves (main stop valve, control
valve ETC).
TURBINE PARTS

40. In electricity generation, a generator is a device that converts mechanical energy to electrical energy for
use in an external circuit.
GENERATOR

41. Working principle of a DC generator: According to Faraday's laws of electromagnetic induction,
whenever a conductor is placed in a varying magnetic field (OR a conductor is moved in a magnetic
field), an EMF (electromotive force) gets induced in the conductor.
WORKING PRINCIPLE

42. OTHER COMPONENTS OF POWER PLANT
 DEAERATOT
A de aerator is a device that is widely used for the removal of oxygen and other
dissolved gases from the feed water to steam-generating boilers.

43.  CONDENSER
The condenser accomplishes this action by the removal of sufficient heat from the hot gas,
to ensure its condensation at the pressure available in the condenser. The heat is shifted to
another medium, like water or air, to cool the condenser.

44.  ASH PRECIPITATOR
ASH precipitator is a filtration device that removes fine particles, like dust.

45.  COOLING TOWER
A cooling tower is a specialized heat exchanger in which air and water are brought into
direct contact with each other in order to reduce the water's temperature.

46.  VALVES
A device for controlling the passage of fluid or steam through a pipe, duct, ETC
 FEED WATER HEATER
A feed water heater is a power plant component used to pre-heat water delivered to a
steam generating boiler.
o HP Heater
o LP Heater
 GOVERNER
A governor, or speed limiter, is a device used to measure and regulate the speed of a
machine, or working fluid.

47.  FEED WATER PUMP
A boiler feed water pump is a specific type of pump used to pump feed water into a
steam boiler. The water may be freshly supplied or returning condensate produced as a
result of the condensation of the steam produced by the boiler.
 HEAT EXCHANGER
A heat exchanger is a device used to transfer heat between a solid object and a fluid, or
between two or more fluids.
 CHIMNEY
A chimney is a structure that provides ventilation for hot flue gases or smoke from a boiler,
stove, furnace or fireplace to the outside atmosphere.

48.  PUMP
A pump is a device which is increase the pressure of a liquid or gas.
 STEAM EJECTOR
In condensing system, steam ejector has function to extract air and other non-
condensing gases from the sealed condenser, and in such way to maintain vacuum
which corresponds to ratio of cooling water quantity, cooling water temperature and
cooling surface. Such steam ejectors can create vacuum up to 98%.
 CALORIFIRE
A calorifire is an indirect fired water heater to provide hot water. Essentially they are
storage water.

49. IMPORTANT POINTS
o Heat Rate is the common measure of system efficiency in a steam power plant. It is defined as
"the energy input to a system, typically in Btu/kWh, divided by the electricity generated, in kW."
Mathematically
o Efficiency is "a ratio of the useful energy output by the system to the energy input to the
system." Mathematically:

50. o It is a term which establishes a relationship between energy supplied to the boiler and
energy output received from the boiler. It is usually expressed in percentage. As a general
rule, “boiler efficiency (%) = heat exported by the fluid (water, steam) / heat provided by
the fuel x 100."
o Pressure Gauge: Pressure gauge indicates the pressure of steam in a boiler.
o Efficiency of Thermal cycle increases by Regeneration & Reheating of Steam.
o Heating of dry steam above saturation steam is known as Super Heating.

51. o The ratio of heat utilized to produce steam & heat liberated in furnace is known as Boiler
Efficiency.
o The overall efficiency of Thermal power plants is Boiler, Turbine & Generator efficiency.
o Size of boiler tubes is specified by outside diameter & thickness.
o Economizer in Boiler decrease fuel consumption.
o Super heating of steam is done at constant pressure.
o Water Boils when its vapor pressure equals that of the surroundings.
o Thermal Efficiency of Thermal power plants is the order of 30%.
o Thermal Efficiency of well-maintained boiler will be 90%.

52. o Fuel cost of thermal power plant is relatively low.
o We can produce thermal energy almost everywhere in the
world.
o Heat production System is simple compared to other system.
o Overall system cost effective.
o Easy mechanism.
o Same heat could be reused.
o Easier Maintenance of power station.
ADVANTAGES

53. o Use of water is prominent here, therefore, any places with supply of water is a perfect location
for installing a thermal power station.
o Thermal power plant requires comparatively small space to be installed.
o Thermal plants can be placed near load centers unlike hydro and nuclear plants.
o Economical in initial cost compared to hydro plants.

54. DISADVANTAGES
o Huge production of Carbon-di-oxide (CO2) in the atmosphere.
o Exhausted gases harms outside environment badly.
o Low overall efficiency.
o Thermal engines requires huge amount of lubricating oil that is very expensive.
o Huge requirement of water.
o Efficiency of thermal plant is less (30-35%).
o Life of the plant is hardly 3 to 4 decades compared with hydro-plant (1 to 2) centuries.

55. SUGGESTIONS FOR IMPROVEMENT
o Maintaining proper vacuum in condenser.
o Using LED lights for lighting purpose.
o Optimizing and attending leakages of instrument & service air.
o Checking of conditions of pumps.
o Optimizing the running of air conditioning system.
o Operating equipment close to design efficiency.
o Ensuring proper working of dampers, soot blowers & burner.
o Selection of Technology.
o By reducing the leakage of steam, flue gas.

56. FEEDBACK
Difficulty Faced during the Training:
o Every month we need to extend our internship because industry do not
give us totally 16 weeks complete internship joining letter.
o After 1 month no specific supervision provided that’s why sometime its
create problems.

57. Feedback Regarding the Curriculum:
o Thanks to the faculty of Mechanical Engineering Technology department for providing us 16
Week’s internship letter
.
o During 4 months internship in thermal power Station, we learnt practically.
o Implementation of the subject theories especially relevant to the subjects.
o It was very good mixture of theoretical and practical training.
o The training was very informative and practically implemented.
o The syllabus was excellently delivered all aspects were clearly explained especially Generation
cycles.

58. THANK YOU