Jamshoro Power Company Limited Brief Reporting by a student of Chemical Engineering Department Mehran UET.

1. VENUE: JAMSHORO POWER COMPANY LIMITED
NAME: AAMIR ALI SEELRO (15CH31)
DEPARTMENT: CHEMICAL ENGINEERING,
MUET, JAMSHORO
DATE: / /2016
Summer
Internship
Report

2. 1
BACKGROUND
This visit aimed to visualize the understanding of the cores of
thermodynamics and chemical process technology in the power
production sectorunder the supervision of Rizwan Ahmed Arain, the
Visit Cordinator. Students, void of engineering applications,
developed an insight of the application of processes and learnt about
the keys issues of the industry. It brought me plenty of practical
works which I’d learnt in my classes
PLANT INFRASTRUCTURE AND UNITS.
The Plant is installed at the prime location of Jamshoro “The City of
Education”, about 18 km away from Hyderabad.
 It holds the capacity to share an estimated capacity about 850 MW
to the national grid of Pakistan.
 850 MW is generated by four separate units contributing about
182,155,155 and 157 MW respectively.
 First plant was commissioned by the Fuji n Electric Company,
Japan that only works on Furnace Oil.
 Other three units were installed by the Chinese firm Harbin Power
Electric Engineering that can operate on Gas and furnace oil.
 This Structure promises to cater the needs of nation efficiently.
 Structure stood very tall as Pump was installed at ground floor and
the boiler at certain elevation and Turbines and turbo generators
on the parallel floor.
 Huge capacity oil containers were protected with sensitivity.
 The Fuel gas exhaust transported through the sealedtunnels to the
high elevation.
 Two Cooling Water plants were also installed.

3. 2
Control Room
 The control room was operated by the professional operators
supervised by operated by the engineers.
 Power Production Rating measurement systemwas equipped
for every separate plant.
 Fire Fighting System was managed automatically.
 Activity of shutting down the system was also managed by
automated room so called control room.
 It held all the numerical analysis and graphical data of the
pros and cons of the power losses, efficiency and other
parameters.
 Frequently used equipment control switches were mounted on
the bench board (where the operator was standing). The back
panels contain indicators, recorders, and controls for less
frequently operated equipment.
 Control room had the full governance of operations of the
processes involved in the Rankine cycle (thermodynamic cycle)
is used in power production industries.
 The JPCL Plant working lay its basics from the Basic Rankine
Reheat Cycles.
 The Plants basic chemistry involves the pump, the boiler; the
turbine and the condenser.
Heating Expansion Condensation
Power Production Cycles

4. 3
 The boiler is the main part of any thermal power plant. It
converts the fuel energy into steam energy. The fuel may be
furnace oil, diesel oil, natural gas or coal. The boilers may be
fired from the multiple fuels. The type of boiler used in the
JPCL UNIT-I (that our group visited) is “water tube type”.
 Turbine is used to convert the heat energy into
mechanical energy. Turbine used in JPCL is impulse-
reaction steam turbine.
 Water is taken in first to the pump as a saturated liquid and
compresses isentropic ally to the operating pressure of the boiler.
 Temperature Changes and heating in boilers expedites as
constant pressure heat additions steams the water.
 Boiler along with other sections are often called the steam
generators.
 The superheated vapor enters the turbine causing work done on
the turbo generators to produce power.
 Steam now drops off to saturated liquid water mixture and
condenses isentropic ally.
 In between this process, Steam is processed through various
special mountings and fittings to ensure safe and efficient
functioning.

5. 4
Since we are the chemical engineers, so we visited and worked upon
the following sections of the power plant.
1. Demi-water plant/ Demineralization plant.
2. Sodium hypochlorite unit.
3. Fuel receiption and testing.
4. Boilers and Chimneys.
DEMI-WATER ‘S PLANT/DEMINERALIZATION PLANT:
As the name suggests this plant situated in the powerhouse is used to
free the water from minerals, like Ca, Mg, Na, Al, Si, K etc. the plant
consists of the large tanks where water is stored, Cation and Anion
exchange resins, tanks for anion and cation exchange called service
tanks and a polisher to polish the demineralized water to cooling
towers, in service tank cathode is generated with HCl 7% and anode
is generated with NaOH. H+ and OH- ions and minerals are
separated and then H+ and OH- are combined to form demi water.
SODIUM HYPOCHLORITE UNIT:
The unit called sodium hypochlorite unit or sometimes also called
chlorination plant provides sodium hypochlorite , a bleaching
substance to the demi water in cooling towers as it kills bacteria ,
removes algae, enables mud to be soluble and limits the contamination
in cooling towers.
The sodium hypochlorite is produced from brine solution through
electrolysis with DC current the water present in solution is directly
proportional to voltage and concentration of brine to the current.
NaCl+H2ONaOCl+H2
The plant also consists of recirculating tank with rubber coating
inside to reduce reactivity between Cl2 and Fe in the tank. Pressure in
Being chemical engineer, I worked upon the following
sections of JPCL.

6. 5
tank (2-4)Pa, electrolyses cells in tank possess flush, the process
completes in 45 minutes.
FUEL RECIEPTION AND TESTING:
Crude oil is used as a fuel for boiler in the powerhouse .crude oil is
brought from oil wells on container trucks, it is stored in large tanks
of160000 tonnes capacity, but before storage is testedin chemical labs,
where viscosity, water %, volatility etc are taken into account, if all
things meet the standard values required, then the fuel is stored and
used for running the plant.
BOILER AND CHIMNEY:
Boiler happened to be the large closed vertical vessel, with flame
injection the intensity of the flame is maintained according to the
requirements, the flame so injected is produced by burning the fuel
(crude oil) , the cool demi water tank is capsulated inside the boiler
vessel , as its temperature increases the steam is produced which is
supplied to the turbine to operate it and the smoke produced in the
boiler with flame injections is left to the environment via large
chimneys .
Process Block Diagram of JPCL
Sodium hypochlorite
unit
Demi water plant
Cooling towers Boiler
Fuel tank
Fuel testing lab
Chimney
Water from River
Indus Smoke to the
atmosphere

7. 6
Clean, safe water is vital for every day life. Water is essential for
health, hygiene and the productivity of our community.
The water treatment process may vary slightly at different locations,
depending on the technology of the plant and the water it needs to
process, but the basic principles are largely the same. This section
describes standard water treatment processes applied in JPCL..
Coagulation / Flocculation
During coagulation, liquid aluminium sulfate (alum) and/or polymer
is added to untreated (raw) water. When mixed with the water, this
causes the tiny particles of dirt in the water to stick together or
coagulate. Next, groups of dirt particles stick together to form larger,
heavier particles called flocs which are easierto remove by settling or
filtration.
Sedimentation
As the water and the floc particles progress through the treatment
process, they move into sedimentation basins where the water moves
slowly, causing the heavy floc particles to settle to the bottom. Floc
which collects on the bottom of the basin is called sludge, and is piped
to drying lagoons. In Direct Filtration, the sedimentation step is not
included, and the floc is removed by filtration only.
Filtration
Water flows through a filter designed to remove particles in the water.
The filters are made of layers of sand and gravel, and in some cases,
crushed anthracite. Filtration collects the suspended impurities in
water and enhances the effectiveness of disinfection. The filters are
routinely cleaned by backwashing.
Disinfection
Learnings from Water Pre-treatment Plant (JPCL)

8. 7
Water is disinfected before it enters the distribution system to ensure
that any disease-causing bacteria, viruses, and parasites are
destroyed. Chlorine is used because it is a very effective disinfectant,
and residual concentrations can be maintained to guard against
possible biological contamination in the water distribution system.
Sludge Drying
Solids that are collected and settled out of the water by sedimentation
and filtration are removed to drying lagoons.
Fluoridation
Water fluoridation is the treatment of community water supplies for
the purpose of adjusting the concentration of the free fluoride ion to
the optimum level sufficient to reduce dental caries. Hunter Water is
required to fluoridate water in accordance with the NSW
Fluoridation of Public Water Supplies Act 1957.
pH Correction
Lime is added to the filtered water to adjust the pH and stabilise the
naturally soft water in order to minimise corrosion in the distribution
system, and within customers’ plumbing.
End