Submitted To: -

Sir. AMMAN ULLA NIAZI

Submitted By: -
HAFIZ ARSALAN HASSAN

DEPARTMENT OF MECHANICAL ENGINEERING & TECHNOLOGY

Muhammad Nawaz Sharif University of Engineering & Technology Multan

 Thermal power plant (Muzaffargarh)

Block 1 Block 2 Block 3

Unit #1 Unit #2 Unit #3 Unit #4 Unit #5 Unit #6

210 (MW) 210(MW) 210(MW) 320(MW) 210(MW) 210(MW)

Russian Russian Russian China China China

Northern Power Generation Company Limited (NPGCL) is a Public Limited Company, incorporated
under the Companies Ordinance 1984, under certificate of incorporation dated October 15, 1998; having
its generation facility at different locations of Province of Punjab Pakistan. Vision and Strategy of
NPGCL is to become a leading Power Generation Company to meet the energy requirement of the
customers through reliable, environmental friendly and sustainable supply of Electricity without
compromising on Safety, quality and plant integrity. Northern Power Generation Company Limited
owns and operates thermal power generation facilities located at Muzaffargarh, Multan and Faisalabad.
Installed capacity of the generating assets is 1,921 MW. A complex pattern of internal and external
factors constrain operating and financial performance of the company. The company has been operating
with a negative bottom line, which has jeopardized sustainability.

Government of Pakistan aims to address the country’s power sector issues by implementing Power
Sector Reform Program. As part of the program the public sector thermal power generation companies
(GENCOs), including NPGCL were required to develop and implement Business Plans to effectively
respond to constraints and obstacles to satisfactory performance.
Before studying cycle first we study the main equipment and their working principle.

1-Steam Boiler
A boiler is a closed vessel in which fluid (generally water) is heated. The fluid does not necessarily boil.
The heated or vaporized fluid exits the boiler for use in various processes or heating
applications, including water heating, central heating, boiler-based power generation, cooking,
and sanitation.

Principle:

The basic working principle of boiler is as follow: The boiler is essentially a closed vessel inside which
water is stored. Fuel (generally coal) is burnt in a furnace and hot gasses are produced. ... Thus, the
basic working principle of boiler is to convert water into steam by using heat energy as input.
Types:

 Water tube boiler ( in which water inside the tube and fire outside the tube)
 Fire tube boiler ( in which water outside the tube and fire inside the tube)
Components of Boiler:
 Boiler shell
 Furnace
 Grate
 Burner
 Ash pit
 Mud Ring
 Safety Valve
 Pressure Gage
 Fusible Plug
 Feed Check Valve
 Steam Stop Valve
But other some parts of Boiler which can increase the efficiency of Boiler but not its
components which are given as
 Re heater
 Super Heater
 Economizer

Turbine:
A turbine is a turbomachine with at least one moving part called a rotor assembly, which is a shaft or
drum with blades attached. Moving fluid acts on the blades so that they move and impart rotational
energy to the rotor.
Principle:
The fluid may be compressible or incompressible. Several physical principles are employed
by turbines to collect this energy: Impulse turbines change the direction of flow of a high velocity
fluid or gas jet. ... The pressure of the gas or fluid changes as it passes through the turbine rotor
blades.
Types:
1-Impulse turbine
2-Reaction turbine
 Components of Turbine:
Turbine Casings

Turbine Rotors

Turbine Blades

Shroud

Turbine Barring device

Turbine Seals

Turbine Couplings

Governor

Lubrication System

Condenser

In systems involving heat transfer, a condenser is a device or unit used to condense a substance from
its gaseous to its liquid state, by cooling it.

Principle:

Condenser, a part of a refrigeration system, is a type of heat exchanger that transforms gas or vapor
into a liquid that transfers heat from the tube to the air near the tube in a very rapid
manner. Condenser work process is an exothermic process, so the condenser temperature is high.

Types:

 Jet condensers (mixing type condensers)

 a. Parallel flow jet condenser.
 b. Counter flow jet condenser (low level)
 c. Barometric or high level jet condenser.
 d. Ejector condenser.
 Surface condensers (non mixing type condensers)
 A. Down flow surface condenser.
Cooling tower:
A cooling tower is heat removal device that uses water to transfer process waste heat into the
atmosphere. All cooling towers operate on the principle of removing heat from water be evaporating a
small portion of water that is recirculated through the unit.

Principle:
Cooling tower works basically on the principle of evaporation. In this process the sensible heat of hot
water is converted to latent heat of vaporization. Thus reducing the temperature of the exposed
surface area of water to the air. ... To create more turbulence sometimes cooling towers have
packings.
Types:
1-natural cooling tower
2-mechanical cooling tower

Components of cooling tower:

Cooling Tower Louvers

Cooling Tower Fill Media

Cooling Tower Fan

Cooling Tower Drift Eliminators

Cooling Tower Gear Box

Cooling Tower Float Valve

Cooling Tower Nozzles

Cooling Tower Basin

Cooling Tower Piping

Cooling Tower Motor

The Bottom Line

Pumps:

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical
action. Pumps can be classified into three major groups according to the method they use to move the
fluid: direct lift, displacement, and gravity pumps.

Principle:

Port size. All pumps use basic forces of nature to move a liquid. As the moving pump part (impeller,
vane, piston diaphragm, etc.) begins to move, air is pushed out of the way. The movement of air
creates a partial vacuum (low pressure) which can be filled up by more air, or in the case of
water pumps, water.
Types of pump:
Components of pump

The Main Parts of a Centrifugal Pump

An impeller.

A volute or diffuser style casing.

A shaft.

Shaft sleeves.

Bearings.

A sealing arrangement.
 Valve:

A valve is a device that regulates, directs or controls the flow of a fluid by opening,

Types:

Bearings:

A bearing is a machine element that constrains relative motion to only the desired motion, and
reduces friction between moving parts.

Types:

 Deep-Groove Ball Bearings. The most commonly used bearings are Deep-Groove Ball Bearings. ...
 Angular Contact Ball Bearings. ...
 Self-Aligning Ball Bearings. ...
 Thrust Ball Bearings. ...
 Spherical Roller Bearings. ...
 Cylindrical Roller Bearings. ...
 Tapered Roller Bearings. ...
 Needle Roller Bearings.
 Work shop study.

Power Hacksaw Machine:

A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered either by its own electric
motor or connected to a stationary engine. Most power hacksaws are stationary machines. Stationary
models usually have a mechanism to lift up the saw blade on the return stroke and some have a
coolant pump to prevent the saw blade from overheating.

The specification of machine is it cuts the rod up to 200mm diameter.

Sheet bending machine:

A bending machine is a forming machine tool. Its purpose is to assemble a bend on a workpiece. A
bends is manufactured by using a bending tool during a linear or rotating move. This machine is used
for making hollow pipes in main workshop. It is fully manual and electrically controlled.

Sheet cutter:

It is a cutting machine used for cutting metal sheets up to 10mm. basically it’s a hydraulic press that
cuts the sheet into pieces.

Pipe bending machine:

Machine used to bend a straight pipe into desired shape using cold bending process with the help of
dies. It can bend up to 100mm dia rod easily.

Shaper Machine:

It is used for making groves in the work part.

Milling machine:

Milling is the process of machining using rotary cutters to remove material [1] by advancing a cutter
into a workpiece.

Lathe machine:

A lathe is a machine tool that rotates a workpiece about an axis of rotation to perform various
operations such as cutting, sanding, knurling, drilling, deformation, facing, and turning, with tools
that are applied to the workpiece to create an object with symmetry about that axis.

There are two different size lathe one is up to 300mm and second is up to 1m

Universal grinding machine:

Universal Drilling Machine”, is a very useful tool for drilling in three Dimensions. The entire
assembly can mount on a table or a wall.
 Steam cycle

 Boiler drum

 Blow down

 Super heater

 HPC (High pressure cylinder)

 Re-heater

 IPC (Intermediate pressure cylinder)

 LPC (Low pressure cylinder)

 Condenser

 Hot well

 Condensate pump

 Steam jet air ejector

 Vent steam condenser

 LPH 1 (low pressure heater)

 Gland steam condenser

 LPH 2

 LPH 3

 LPH 4

 Dreater Tank (D7)

 Feed pump

 HPH 5 (High pressure heater)

 HPH 6

 HPH 7

 Economizer

 Boiler drum
Boiler drum:

It is a large drum at the top of boilers. A steam drum is a standard feature of a water-
tube boiler. It is a reservoir of water/steam at the top end of the water tubes. The drum stores
the steam generated in the water tubes and acts as a phase-separator for the steam/water
mixture. It is filled half.

Super Heater:

After going through boiler the steam is not saturated to making steam saturated it passes
through different super heater

HPC:

After making the steam from Boiler it hit to the high pressure turbine. This type of Turbine
have 12 stages.

Detail:

Name; triple trendum compound turbine

Speed; 3000 RPM

In let temperature; 541ᵒC

Outlet temperature; 325C

Pressure in; 184.4

Pressure out; 37.5

Re-heater:

The exhaust steam from h.p going to re-heater to increase the pressure and temperature.

Detail:

Flow; 837 t/h

Pressure; 37.5 to 39.5

Temperature; 325 to 541

I.P.C:

Then Steam going to the IP turbine. Where it has 11 stages .it purpose same as HP. And then
going to the LP turbine.

After passing these turbine the pressure and temperature down temperature become 169C and
pressure become 0.92.

Condenser:

After passing through the LP turbine going to condenser in which steam condensed into
water.
Hot well:

The whole condensed water store in the hot well.

Condensate pump:

These pumps condensate water from Hot well to further process or reused make up water

There are three pumps. Which can only one flow rate is 320 T/H and pressure increase to 14-
15 kg/cm2. It is centrifugal pump

Pumps are helps the water to passing through different low pressure heater, steam jet air
ejector, vent steam condenser. And last send to the D7 tank.

These different equipment are helps us to increase the temperature water for Improvement of
boiler efficiency.

D7 (Dreater tank):

A dreater tank is a device for air removal and is used to remove dissolved gasses from boiler
feed water to make it no corrosive. A dereater typically includes a vertical domed deration
section mounted on top of a horizontal cylindrical vessel which serves as dereated feed water
tank. The tank capacity is 100m3.

Feed water pump:

They push the feed water from many high pressure heaters and economizer to the boiler
drum.

Detail:

Pressure; 180

Flow; 380 t/h

Stage; 11

Impeller; 11

Pump; 3 which are coupled by motor through hydraulic coupling.

Water going through high pressure Heater and economizer and then going to boiler drum.

Economizer:

It is present of the above the for burner. In which Flue gases are pass which are increase the
temperature of water and flue gases become cold but not only reduce temperature. The
demnerlize water become temperature only about 240C.
 Flue gases cycle

Fire triangle

1-Air

2-Teprature

3-Fuel

Air

Coming from turbine hall because the temperature of natural gas is high as compared to the
outside the turbine hall.

Fuel

Fuel is coming from the Fuel tank. There are three types of Fuel used in thermal power plant
Muzaffargarh.

I. Heavy furnace oil

II. Diesel

III. Natural gas

But only heavy furnace oil is used most and other used only to running the plant to
achievement the design efficiency.

 F.D fan (force draft fan)

 Burner / furnace

 Super heater

 Reheater

 Economizer + GRC fan Burner

 RAH

 I.D fan (induced draft fan)

 Stock / chimney.
 Cooling water cycle

 Pump

 Condenser

 Cooling tower

 Pump

Making water demineralize water

 Tube well

 Pump house

 RO Plant

 Cation filter (3)

 Anion filter (4)

 Cation filter (2)

 Mix bad filter (2)

 Water tank demineralize (3)