Report on Industrial Visit at

KHEDAR POWER PLANT HISAR (HPGCL)

11TH OCTOBER, 2017

For 5th Sem. ME and 7TH Sem. ME Students

RAO PAHLAD SINGH COLLEGE OF ENGINEERING & TECHNOLOGY

INDUSTRIAL VISIT @ khedar THERMAL POWER Station HISAR (HPGCL) Department Of Mechanical Engineering is one of the most reputed Department in RPS Engineering College Balana and known for its excellent record in academic and co-curricular activities. The state of the art facilities and competent faculty provide an excellent climate for the all-round development of the students. As a part of the curriculum, the students are required to undertake industrial visit to a few industries of repute. As a Head I feel, it will be fruitful that the students with academic background have a glimpse of the industry in order to have a better appreciation of practical applications of theory. Once again Mechanical Department conducted an INDUSTRIAL VISIT for students of 3rd Year and 4th Year. On receiving the letter of permission from KHEDAR THERMAL POWER PLANT , HISAR (HPGCL) a Batch of 49 Students from Mechanical Engg. with 2 faculty members including Dean Sir went on an industrial visit to Khedar Thermal Power Station, Hisar (Haryana) on 11 October 2017. Officers from Plant received students at the entrance and gave a brief introduction of the Plant. They divide students in two groups. Then they took students from one section to the next and explained the process involved in the production of 220KV Electricity. There are total 1200 MW electricity produced for which there are two Plant of each 600 MW.They showed how steams are used to rotates large Turbines and Boilers etc. A few engineers were also employed to do certain repetitive minor operations by using PLC & SCADA softwares in the Control Room . Our students asked many questions & queries from them, they gave good and interesting answer to them. At last all went to SWITCHYARD, where students knew how the produced electricity is distributed to cities and villages. It was an informative, interesting and a successful visit. They appreciated management keen interest and the knowledge of the students about the production technology. As students of ENGINEERING, They learned a few mechanical, electronic application and electrical techniques. Students express thanks to our Director Sir Dr. M. K Yadav, Dean Academic Affairs Sh. R. S Yadav Sir and Training and Placement Officer Mr.Vikash who permitted them to go on the visit, the faculty members (Mr. Manoj) who accompanied them and the officials who explained the various departments.

Introduction to the Rajiv Gandhi Thermal Power Station

Rajiv Gandhi Thermal Power Station is located at Khedar in Hisar district of Haryana. The power plant is one of the coal based power plants of HPGCL.

The Engineering, procurement and construction contract is given to Reliance Infrastructure. Boiler, Turbine and Generator was supplied by Shangai Electric Corporation (SEC), China. Balance of Plant was supplied by indigenous suppliers. Multiple consultants (CEA, Desein,NTPC & DCPL) were associated with the project.

Plant Features: The work for a 1200 MW coal-fired power plant was awarded during 2007. The total estimated cost of the project is around Rs 4297 crores. The cost of Rs 3.19 crore per MW for this project is lowest among all the power plants. Both the units 2x600 MW were commissioned.The total estimated cost of the project is Rs. 4512 crores.

Name and Address Units Capacity Date of commissioning

Rajiv Gandhi Thermal Power Project (RGTPP), Khedar, Hisar

Phone: 01693-

Fax: 01693-243555

Unit-I 600 MW 24.08.2010

Unit-II 600 MW 01.03.2011

Installed Capacity 2 X 600 MW

Available Land 989 acres

Location Khedar,Hisar

EPC Contractor M/s Reliance Energy Ltd,

EPC Cost Rs 3775.428 crore (total estimated cost Rs.4512

crore)

Administrative approval 31.12.2005

Project Consultancy M/s Desein was appointed Project Consultant and

CEA were engaged as Review Consultants

Coal Sources M/s Mahanadi Coalfields Ltd., Orissa

Equity contribution State Govt. is contributing 20% equity for the

project vide letter dated 10.10.2002. Balance 80%

has been arranged through PFC.

Issue of LOI Issued to M/s REL vide letter dated 29.01.2007

MAJOR COMPONENTS SPECIFICATIONS:

(I) Steam Turbine: Steam turbines have been used predominantly as prime mover in all thermal power stations. The steam turbines are mainly divided into two groups: - • Impulse Turbine • Impulse-reaction Turbine OR Reaction Turbine The turbine generator consists of a series of steam turbines interconnected to each other and a generator on a common shaft. The turbines are in 3 stages of High Pressure Turbine, Intermediate Pressure Turbine & Low Pressure Turbine.

(a) High Pressure Turbine: It consists of a total of 19 stages out of which 1st stage is

Impulse Type while remaining 18 stages are of Reaction type. The inlet conditions are, 520 ˚C temperature & 150kg/cm2 pressure. The outlet conditions are, 340 ˚C temperature & 40kg/cm2 pressure.

(b) Intermediate Pressure Turbine: It consists of 17 Reaction Turbine stages. The inlet

conditions are 533 ˚C temperature & 37kg/cm2 pressure.

(c) Low Pressure Turbine: It consists of 16 Reaction Turbine stages.

The specification of Steam turbine used in the plant is: Make : BHEL, Kraft Work Union Design Rated Load : 250MW Max Load under valve wide open : 262MW Construction : Three Cylinder Reheat Condensing Turbine

(II) Boiler: A Boiler or steam generator essentially is a container into which water can be fed and steam can be taken out at desired pressure, temperature and flow. This calls for application of heat on the container. For that the boiler should have a facility to burn a fuel and release the heat. The specification of Boiler used in the plant is: Manufacturer : BHEL (C.E. Design) Type : Natural circulation, Balance draft, double pass, Single drum, Single reheat, direct pulverized coal fired water impounded bottom. (Gas firing & gas regulating system, provision for future) Boiler design (Pressure & Temp) : 182.5 Kg/cm2 & 5400 C Boiler Designation : 1524019963.51150614263.5 Type of firing : Tilting tangential

ENVIRONMENT SAFEGUARDS: 1) To prevent Air Pollution • ESP of 99.9% efficiency for collection of fly ash from flue gases. • Online monitoring of emission levels of SOx, NOx, and TPM in Flue gas. • Four Ambient air quality monitoring Stations to measure SPM, RSPM, SOx, NOx, Along with one meteorological station for weather monitoring. • Mobile Van to monitor Ambient Air quality in remote areas. 2) Ash Disposal • Four ash ponds for disposal of ash slurry. • Pond management designed to minimize pollutants in discharge effluent. Dry Fly Ash

collection System for maximizing ash utilization. 3) Health and Safety Management • Health & Safety Policy in place. • Emergency plan and Disaster Management system is in place. Occupational Health

Management and check-ups. • Advanced fire protection system and equipment. • A First Coal fired TPS to achieve Four Star in British Safety Council ranking. 4) Green Belt Development: • To mitigate air pollution levels, a green belt has been developed around the project area. The

development plan was devised after detailed studies and the high volume of tree plantations over the years is a credible effort.

CONCLUSION: The Industrial Visit to the Khedar Thermal Power Plant, Hisar was highly successful. Students received insight of the whole plant right from the raw material (coal) procurement, processing, combustion and generation & transmission of electricity. The whole process was explained in-detail by the representative with detailed description about each equipment with their specifications. A doubt solving session with the Control Room Incharge cleared all students’ queries. This kind of industrial exposure helped students to absorb the theoretical aspects of Thermal & Fluid Power Engineering more efficiently. I would highly appreciate more such visits in the future.

Glimpse of The Visit:

This Industrial Visit adds one more milestone to Students journey.

Student List of Industrial Visit 11.10.2017(Khedar Power Plant Hisar) Sr No. College Roll No Name of student Father's Name

1 15ME02 ABHISHEK YADAV RAMJAS YADAV

2 15ME03 AJIT YADAV SOHAN LAL

3 15ME08 ASHISH KUMAR SATYAPAL SINGH

4 15ME09 ASHWANI SHIV KUMAR

5 15ME11 BIJOY MILI BUDHESWAR MILI

6 15ME12 CHANDER MOHAN SUNDER LAL

7 15ME13 DEEPAK YADAV GHANSHYAM YADAV

8 15ME14 DEVENDER SINGH AJEET SINGH

9 15ME17 GAURAV KUMAR HARINDER SINGH

10 15ME18 GOVIND YADAV PRADEEP KUMAR

11 15ME20 HIMANSHU RAJPAL

12 15ME24 JITENDER RAJBIR SINGH

13 15ME25 KANDARPA DUARAH JIBA DUARAH

14 15ME27 LAKSHYA SWAMI SURENDER KUMAR

15 15ME30 MANDEEP SINGH KARAMVIR SINGH

16 15ME34 MITHLESH KUMAR FULU MAHTO

17 15ME38 MONU YADAV OMPARKASH

18 15ME39 MUKESH BABU LAL

19 15ME40 NAVEEN LAKSHMAN

20 15ME43 NIPUN SHARMA PAWAN SHARMA

21 15ME46 PRADEEP KUMAR RAMJEE SAHANI

22 15ME49 RAHUL TULSI RAM

23 15ME51 RAHUL SAINI HUKAM CHAND

24 15ME54 ROBIN SINGH BALWANT SINGH

25 15ME55 ROHIT PRADEEP KUMAR

26 15ME56 ROHIT KUMAR SUBHASH CHAND

27 15ME58 SAJAL MANIRAM

28 15ME61 SHUBHAM GOYAL HARISH GOYAL

29 15ME62 SOMBIR SWAMI ATTAR SINGH SWAMI

30 15ME71 VINESH ASHOK KUMAR

31 15ME75 SHASHI YADAV SATYAPAL YADAD

32 L16ME82 SUNIL KUMAR OM PARKASH

33 14ME07 AMIT KUMAR SUMER SINGH

34 14ME10 ANKIT RAJESH

35 14ME17 BHAN SINGH VED RAM

36 14ME24 DEEPAK YADAV DALIP SINGH

37 14ME25 DEVRAJ SOLANKI SURESH SOLANKI

38 14ME37 KARAN SINGH DILBAG SINGH

39 14ME38 KIRODI MAL SHEORAM

40 14ME47 MANISH KUMAR KRISHAN KUMAR

41 14ME49 MD QUASIM MD. MOZAHIR HUSAIN

42 14ME65 PANKAJ KUMAR RISHIPAL

43 14ME85 RAVI YADAV RAJBIR YADAV

44 14ME106 UDHAM SINGH UGARSAIN TANWAR

45 14ME108 VIKAS VIKRAM SINGH

46 L15ME127 RAHUL KUMAR VINOD KUMAR

47 L15ME129 NEERAJ RAMNIWAS

48 L15ME130 RAHUL BRAHAM DEV

Thank You.

With Best Regards Mr.Rajesh Rana Asstt.Professor & Head Department of Mechanical Engineering Rao Pahlad Singh College of Engineering & Technology