`

POWER PLANT
VISITING-REPORT

SUBMITTED TO:

Sir Zubair Afzal

SUBMITTED BY:

Mehwish Khan, Ahsan Mazhar

REG NO:

2020-UET-NFC-FD-MECH-( 01, 24)

DEPARTMENT:
MECHANICAL ENGINEERING

SUBJECT
Power Plant-LAB

NF
IEFR
 ACKNOWLEDGEMENT

We wish to express our sincere appreciation to those who contributed to the completion of this lab report.

Firstly, we are grateful to Sir Zubair Afzal for their invaluable guidance and support throughout this visit.
Their expertise and feedback significantly improved the quality of this report.

We would like to acknowledge the laboratory staff for their technical assistance, which ensured a safe and
productive environment for our work.

Lastly, we appreciate the understanding and encouragement of our friends and family during the challenging
phases of this visit.

The combined support and efforts of these individuals played a vital role in the completion of this lab report.

Thank you
Mehwish Khan
2020-UET-NFC-FD-MECH-01

Ahsan Mazhar
2020-UET-NFC-FD-MECH-24
 “VISITING REPORT”
 INTRODUCTION:

Genco 3 Faisalabad is a thermal power generation facility located in Faisalabad, Punjab, Pakistan. It is
owned and operated by Northern Power Generation Company Limited (NPGCL), one of four power
generation companies in Pakistan.

 Installed capacity: 1,921 MW (total for NPGCL, of which Faisalabad contributes a portion)

 Fuel type: Primarily natural gas, with options for alternate fuels like high-speed diesel (HSD).

 Units: Includes gas turbines (GTPS) and steam power stations (SPS).

 History: Established under the former Water and Power Development Authority (WAPDA) and
later became part of NPGCL after restructuring in 2007.
 Main Parts of Genco-III Gas power plant:

1. Daily oil tank:

2. Inlet/outlet air Filter:
3. Compressor:
4. Combustion Chamber:
5. Turbine:
6. Generator:
7. Combine Cycle:
8. Transformers:

(Fig#1 - Genco III Gas Power Plant)

 Parts of Gas Turbine:
The main parts of the gas turbine are given below
1. Filter House:
2. Axial Flow Compressor:
3. Combustion Chamber:
4. Gas Turbine:
 Turbine process:

(Fig#2 - Processes)
 Process:
The first 20% rotation of the turbine is completed by the exciter generator or 350MW motor.
20% to 60% of speed the flame occurs which burns the furnace oil and the hot gasses are produced to rotate
the generator shaft.

 Fuel types:

The fuel types used by GENCO III, which includes the Faisalabad power plant, vary depending on the
specific facility and available resources. However, here's a breakdown of the general fuel types:

 Primary Fuel:

 Natural gas: This is the preferred fuel for most of GENCO III's gas turbine power stations (GTPS)
due to its cleaner and more efficient burning compared to other options.

 Alternate Fuels:

 High-speed diesel (HSD): This is primarily used as a backup fuel when natural gas is unavailable or
too expensive. It is also sometimes used in steam power stations (SPS) alongside natural gas.
 Residual fuel oil (RFO): While not as common as HSD, some GENCO III facilities, like Nandipur
Power Plant, use RFO as an alternative fuel.

Specifics for Faisalabad Power Plant:

 Gas Turbines (GTPS): Primarily use natural gas with HSD as a backup.
 Steam Power Station (SPS): Can use natural gas with HSD and RFO as alternate options.

 HSD OIL:
The system is operated using High-speed Diesel (HSD). The daily reservoir is utilized for the storage
of the oil consumed during a given day. The capacity of the object in question is 5500 liters. Two filtration
mechanisms are employed to cleanse the oil. The A.C motor is employed to facilitate oil flow, while the
D.C motor serves as a contingency option.


 (Fig#3 -Fuel Tank)
 GAS:
Natural Gas is mostly used in the system. The gas pressure should be 14-16kb. The gas is mostly
used due to being cheap as compared to HSD.
 Inlet/outlet air Filter:
The Inlet/outlet Filters are specially developed for gas turbine compressors. The filters are built to
protect the gas turbine against pollution in the air and resist moisture. It consists of 416 approx. and their use
full life is around 2 years.

(Fig#4 - Air Filter Room)

(Fig#5 - Inlet Air Filter)

 Gas power plant Compressor- GENCO III:
The compressor receives air through air inlet filters
and directs it into the combustion chamber. The air undergoes various stages and achieves specific pressure
and temperature levels. At each successive stage, the temperature and pressure increase in a consistent ratio.
The compressor is equipped with a total of 16 stages, and its compression ratio ranges from 1 to 10 bars.
Therefore, when the inlet pressure is 1 bar, the compressor exit pressure will increase to 10 bar,
accompanied by a temperature rise of 450 ⁰C.

 Working of Combustion chamber:

The combustor chamber is a specified area within a gas turbine
where the process of combustion occurs. Within the combustion chamber, the process involves the mixing
of compressed air with fuel, which leads to the combustion of the resulting mixture. The combustion
chamber is an integral component of a turbine system, helping the conversion of chemical energy into
thermal energy. Certain gas turbines are equipped with a total of 14 combustors, through which the hot gases
flow before entering the turbine.

(Fig#6 – Combustion Chamber)

 Liner:
The liners are used to control the fire in the system. 8-10 liners are used in each gas turbine. The air
is mixed with flame and burns the gasses.

 Fishtail:

The fishtail-shaped pipes are used to put the hot gasses at the turbine to rotation.

(Fig#7 – Fishtail Pipe)

 Gas Turbines:
A turbine is a machine that is designed to convert chemical/fuel energy into mechanical power.
The 5100-rpm turbine is used in the gas turbine.

(Fig#8 – Turbine)
 Types of Turbines:
There are two types of turbines given below:
 Impulse Turbine.
 Reaction Turbine.

(Fig#9 – Types of Turbine)

 Turbine Generator:
A generator is a machine that converts mechanical energy into electrical energy. The
generator shaft is coupled with the turbine. The generator is 32 MVA. And generate 11kv with 50Hz
frequency.

 Parts of Generator:
The main parts of the generator are given as follows:

1. Rotor & Stator:

2. Casing & Bearing:
3. Exciter:
Rotor:
This is the rotating part of t h e generator and field winding is nested upon it, this is coupled
with the turbine shaft.

Stator:
This is the stationary part of the generator and stator winding is nested in it, this is coupled through
the bus bar to the system.

Frame:
 The generator frame contains rotor winding, stator winding, and bearing. The generator frame
restricts the outer element from getting into the generator casing. This also prevents from expulsion of
hydrogen and provides heavy support.

Bearing:
The bearing shares the load of the generator rotor and prevents excess radial movement.
 Synchronize Process:
When two different electrical systems are coupled together it is called
synchronization or to connect the generator with the system.

(Fig#10 – Synchronization)
 Synchronization requirement
There are three main aspects of synchronization

1. The generator and system voltage should be the same.

2. Generator and system frequency should be the same.
3. The generator and system phase angle should be equal.
For synchronization, an Automatic Voltage Regulator is used for excitation. Phase sequence, Voltage Level
and frequency should same for synchronization.

 Combined cycle plant:

 Working principle:
A combined cycle power plant is at the end of the gas turbine. This plant produces 50% more electricity
from the same fuel with the exact of 480’C, this is used in a combined cycle and gets 47 MW power in
GTPS. The waste heat from the gas turbine is used in the boiler to produce the steam and this steam rotates
the steam turbine, and the turbine is coupled with the generator shaft.

(Fig#11 – Combined Cycle plant)

 Switchyard:
A switchyard is a collection of electrical equipment where high-voltage electricity is switched using various
components. Electrical switchyards are usually part of a substation where electricity is transformed from one
voltage to another for transmission or distribution. Switchyard provides the facilities for switching,
Protection & and control of electric power.
A switchyard is essentially a hub for electrical power sources. For instance, a switchyard will exist at a
generating station to coordinate the exchange of power between the generators and the transmission lines in
the area. A switchyard will also exist when high-voltage lines need to be converted to lower voltage for
distribution to consumers. The function of an electrical switchyard is to deliver the generated power from
the power plant at the desired voltage level to the nearest grid. In Another way, we can simply switch the
received power supply from various generating stations to various locations concerning their requirement.
Therefore, a switchyard will contain; current-carrying conductors, grounding wires and switches,
transformers, disconnects, isolators, remotely controlled arc snuffing breakers, metering devices, etc.

 Components & Devices:

• Bus bar:
• Bus couplers:
• Feeder:
• CT & PT:
• Power transformer:
• Isolators:
• Breakers:
• Lightening arrestor:

 Bus-bar:
These are connecting bars that are connected to various local and distribution feeders and also intact
with supply sources. OR Those conductors that receive source supply and distribute to different lines

(Fig#12 – Bus Bar)

 Bus Coupler:
Double bus scheme, where two bus bars are installed a provision of bus coupler has been
provided. Therein a bus coupling circuit breaker with two isolators is called a bus coupler. Its prime function
is to substantiate the supply on any bus bar without disconnecting with system.
 Feeder:
The feeder is used to connect the electricity to the consumer. This has a vital role in the power
system.
 CT/PT (Current and potential transformer)

These are also called instrument transformers. These are used to measure the voltage and current of
different high-voltage lines.
CT is a type of instrument transformer that is used in power systems for measurement, detection, and
protection of the system. Current transformers are used extensively for measuring current and monitoring
the operation of the power grid. Current transformers, together with voltage transformers (VT) (potential
transformers (PT)), are known as instrument transformers.it is a device used to measure large currents by
scaling a large primary current to a smaller, easy-to-measure, secondary current. Current or voltage
instrument transformers are necessary for isolating the protection, control, and measurement equipment
from the high voltages of a power system, and for supplying the equipment with the appropriate values of
current and voltage - generally, these are 1A or 5Α for the current coils and 120 V for the voltage coils.
 Isolator:
Isolators are used in electrical substations to allow the isolation of apparatus such as circuit breakers
transformers, and transmission lines, for maintenance. Often the isolation switch is not intended for normal
control of the circuit and is used only for isolation. This can be termed as off load switch Isolator is also
capable of switching with the charging current and also breaks the bus transfer current which is its
functional requirement. An isolator switch is used to make sure that an electrical circuit can be completely
de-energized for service or maintenance.

 Breaker:
A circuit breaker is an automatically-operated electrical switch designed to protect an electrical circuit
from damage caused by overload or short circuits. Its function is to interrupt continuity, to immediately
discontinue electrical flow. In the switchyard, High-Capacity Circuit Breakers are used. It works on
overload.
A circuit breaker is a piece of equipment which can

1. Make or break a circuit either manually or by remote control under normal conditions.
2. Break a circuit automatically under fault conditions.
3. Make a circuit either manually or by remote control under fault conditions.

 Lightening arrestor:
A lightning arrester is a device to protect electrical equipment from over-voltage transients
caused by external (lightning) or internal (switching) events. Also called a surge protection device (SPD)
or transient voltage surge suppressor (TVSS). A lightning arrester is a device used on electrical power
systems and telecommunication systems to protect the insulation and conductors of the system from the
damaging effects of lightning. The typical lightning arrester has a high-voltage terminal and a ground
terminal. When a lightning surge (or switching very similar surge) travels along the power line to the
arrester, the current from the surge is diverted through the arrestor, in most cases to Earth.

 Power Transformer:
This is a stationary device even though no part of this device is Rotating. This
operates on the law of mutual induction. According to Faraday’s law if the current is supplied in one coil
due to mutual Induction the supply will automatically enter into the second coil. Transformers work on
this law and transform the current from high to Low voltage or low to high voltage. The coil in which the
current is supplied is called the “Primary coil” and the receiving coil is called the “Secondary coil”. The
 transformer can be stepped up or stepped down. Transformers are used to reduce or improve the generator
voltage which is further supplied to the system.
 Parts of Transformer:
The main parts of the Transformer are the following

1. Conservation tank.
2. Breather.
3. Primary winding.
4. Secondary winding.
5. LT terminal.
6. HT terminal.
7. Iron core.
8. Transformer cover.
9. Oil cooler.
10. Cooling fans.
11. Tap changer.

 Cooling system:

 ON, AN (oil natural, air natural).

 ON, AF (oil natural, air forced).
 OF, AF (Oil force, air force).
 OF, AN (Oil force air natural).

 Bucholz relay:
This relay has been installed in between the conservator tank and transformer. This prevents the
transformer from every kind of internal fault that can occur by short-circuiting winding and core terminals.
Due to a short circuit, the oil gets overheated and consequently, gasification will occur. These gases travel to
the conservative tank thereby Bucholz relay has been placed. The mercury switches will be operated which
subsequently operate the primary and secondary circuit breaker and generator breaker. It is also called gas
operated relay.
 Relay:
The relays are used for the production of the system.
 Relays types:
The two types of relays are used
 1. Fix time relay.
 2. Inverse time relay.

 Relay’s working:
The working of the relay depends on the signal of P.T and C.T, the D.C supply, and the period. The relay
should be healthy to produce the system.

• Relay using in R.E.

• Under excitation relay.
• Reverse power relay.
• Differential current relay.
• Generator over current relay.
• Condenser over current relay.
• Negative phase sequence.
• Earth fault/220-volt D.C fail.
• Generator winding temp high.
 Steam power plant:
A thermal power station is a power plant in which the prime mover is
steam-driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical
generator.

(Fig#13 – Line diagram of Steam Power Plant)

 Basic parts of steam power plant:

The basic parts are given as the following:
 BOILER.
 TURBINE.
 GENERATOR.

 Boiler:
A boiler or steam generator is a device used to produce steam by applying heat energy to
water. Thus, when heat is applied it produces steam and pressure in closed vessels.

 Types of boilers:
 Water tube boiler.
 Fire tube boiler.

 Water Tube Boiler:

In the water tube boiler, boiler feed water flows through the tubes and enters
the boiler drum. The circulated water is heated by the combustion gases and converted into steam in the
vapor space in the drum. These boilers are selected when the steam demand as well as steam pressure
requirements are high.

(Fig#14 – Water tube boiler)

 Fire Tube Boiler:

In the fire tube boiler, hot gases pass through the tubes, and the boiler feed
water in the shell side is converted into steam. Fire tube boilers are generally used for relatively small
steam capacities and low to medium steam pressures.

(Fig#14 – Fire Tube boiler)

 Parts of Boiler:
The main parts of the boiler are given as follows:
1. Boiler Drum.
2. Boiler Furnace.
3. Super Heaters.
4. Re-heaters.
5. Boiler water tubes.
 6. Air preheater.
7. F.D Fan.
8. Chimney.
9. Boiler safety valves.
10. Down comers.
11. Lower header / Drum.

 Efficiency of the power plant:

The open cycle has an efficiency of 24-27%. (70 % of the power of turbine is used by compressor)

Combine cycle has an efficiency of 42%.