WINTER INTERNSHIP REPORT(15DAYS) AT JPCL JAMSHORO,

SINDH

o SUBMITED BY:FARHAN HUSSAIN (17ME74)

o DEPARTMENT OF MECHANICAL ENGINEERING, MUET JAMSHORO

o PROGRAM : B.E MECHANICAL ENGINEERING (2ND YEAR)

o SUBMITED TO : SIR RIZWAN AHMED ARAIN

Acknowledgement

It was a unique experience to be in Jamshoro Power Company

Limited(JPCL) and to study an interesting working of plant,it is unique
un forgot able experiance 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 JPCL 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

JPCL generally known as 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. Jamshoro Power Company
Limited(JPCL) 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 center 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 must supply high temperature and high pressure steam
at the inlet of the turbine. As the turbine absorbs energy from the steam,
its temperature and pressure drops toward the outlet. The rotor blades of
steam turbine are having Aerofoil shape for 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) High Pressure (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 pressure of 540 C and 132 kg/cm2
respectively. At the outlet of HP Turbine, the temperature drops to 350 C. For increasing the efficiency of
Thermal power plant, we add more heat 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 from IP Turbine, the steam goes to LP turbine for final turbine processing.
At the outlet of LP Turbine, the temperature and pressure of steam has dropped to 0.2 kg/cm 2 and 50 C
respectively. A condenser is set below the LP Turbine, where the low pressure and low temperature steam is
transferred. The rotor of Steam Turbine will rotate at a speed of 3000 rpm.

Total 8 Extractions are drawn from Steam Turbine. 2 from HP, 4 from IP,
and 2 from LP steam Turbine. These are drawn for pre-heating purposes.

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(3) Condenser :

The low pressure and low temperature steam from the outlet of LP steam
turbine enters the inlet of Condenser. The condenser condenses the steam
from the exhaust of the LP turbine into liquid to allow it to be recycled. A
surface condenser is used at TPS, Jamshoro. The surface condenser is a shell
and tube heat exchanger in which cooling water is circulated through the
tubes. The exhaust steam from the low-pressure turbine enters the shell,
where it is cooled and converted to condensate (water) by flowing over the
tubes. The pressure inside the condenser is maintained at 0.2kg/cm 2. The
condenser generally uses Circulating Cooling Water from a Cooling Tower to
reject waste heat to the atmosphere.
After that, the condensate is stored in a Hot Well from where, it is pumped to
the LP (Low Pressure) Heaters through Condensate Pump. 4 LP heaters are
used for each Unit at TPS, Jamshoro. They are used to pre-heat the condensate at
Low pressure than atmospheric pressure and raise the temperature from 50 C to
150 C. These 4-LP heaters work on the 2- Extraction lines from LP and 2 from IP
steam turbines. After pre-heating of Condensate at low pressure, it is sent to the
Deaerator. A Deaerator is a device that is widely used for the removal of oxygen
and other dissolved gases from the 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

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