This document is a 14-day internship report submitted by Meer Muhammad to Sir Rizwan Arain about their time at the JPCL Jamshoro Thermal Power Station in Sindh, Pakistan. It provides an overview of the major mechanical components of the power station, including the boilers, steam turbines, condenser, feedwater pumps, cooling towers, fans, and flue gas stack. It concludes that the internship was a valuable learning experience that provided insight into the interesting procedures and equipment used at a thermal power plant.

1. WINTER INTERNSHIP REPORT DEC16-JAN17 (14DAYS)
AT JPCL JAMSHORO, SINDH
SUBMITED BY : MEER MUHAMMAD (16ME131)
DEPARTMENTOF MECHANICAL ENGINEERING, MUET JAMSHORO
PROGRAM :B.E MECHANICAL ENGINEERING (2ND
YEAR)
SUBMITED TO : SIR RIZWAN ARAIN

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Acknowledgement
It was a unique experience to be in thermal power station Jamshoro
and 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/h
Steam max temp=540 C
Heating surface of SH and economizer=17533
Furnace 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 the
Steam Turbine, we mustsupply high temperature and high pressuresteamat
the inlet of the turbine. As the turbine absorbs energy fromthe steam, its
temperature and pressuredrops toward theoutlet. The rotor blades of steam
turbine are having Aerofoil shapefor converting maximum amount of thermal
energy of steam into mechanical energy of turbine rotor. High Capacity Power
Plants use different stages of Steam Turbine as:
a) HighPressure (H.P) Turbine
b) Intermediate Pressure (I.P) Turbine
c) Low Pressure (L.P) Turbine
The steam first enters at the inlet of HP Turbine with a temperature and
pressureof 540 𝑜
C and 132 kg/cm2 respectively. At the outlet of HP Turbine,
the temperature drops to 350 𝑜
C. For increasing the efficiency of Thermal
power plant, we add moreheat to the steam through Re-Heaters situated in
Boiler. 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 fromIP Turbine, the steam goes to LP turbine for final turbine
processing. Atthe outlet of LP Turbine, the temperature and pressure of steam
has dropped to 0.2 kg/cm2 and 50 𝑜
C respectively. A condenser is set below the LP
Turbine, wherethe low pressureand low temperature steam is transferred. The
rotor of Steam Turbine will rotate at a speed of 3000 rpm.
Total 8 Extractions are drawn fromSteam Turbine. 2 fromHP, 4 fromIP, and
2 fromLP steam Turbine. These are drawn for pre-heating purposes.

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(3) Condenser :
The low pressureand low temperature steam fromthe outlet of LP steam turbine
enters the inlet of Condenser. The condenser condenses the steam fromthe
exhaust of the LP turbine into liquid to allow it to be recycled. A surface
condenser is used at TPS, Jamshoro. Thesurfacecondenser is a shell and tube
heat exchanger in which cooling water is circulated through the tubes. The
exhaust steam fromthe low-pressureturbineenters the shell, whereit 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 froma Cooling Tower to reject wasteheat to the
atmosphere.
After that, the condensateis stored in a Hot Well fromwhere, it is pumped to
the LP (Low Pressure) Heaters through CondensatePump. 4 LP heaters are
used for each Unit at TPS, Jamshoro. They are used to pre-heat the condensate at
Low pressurethan atmospheric pressureand raise the temperature from50 C to
150 C. These 4-LP heaters work on the 2- Extraction lines fromLP and 2 fromIP
steam turbines. After pre-heating of Condensate at low pressure, itis sent to the
Deaerator. A Deaerator is a device that is widely used for the removalof oxygen
and other dissolved gases fromthe 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)
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 through
Flue Stack.

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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
Overall Thermal Power Plant Layout