International Journal of Advanced Engineering Technology

E-ISSN 0976-3945

Research Article

THERMODYNAMIC ANALYSIS OF GANDHINAGAR

THERMAL POWER STATION
a

Prof. Alpesh V. Mehta*, bMr.Manish Maisuria, cMr.Mahashi Patel

Address for Correspondence

Asst.Prefessor, G.H.Patel College Of Engineering And Technology, V.V.Nagar

b,c
Students, G.H.Patel College Of Engineering And Technology,
V.V.Nagaravmehta2002@yahoo.co.in,alpeshmehta@gcet.ac.in
ABSTRACT
Energy and environment both are core for human comfort and peripheral for global survival now-a-days.
Modern economic pressure demands re-examination of the existing power generating plants for various options
for their techno-economical and efficient operations. This paper presents a detailed energy study based on the
first law analysis of the coal fired thermal power station namely Gandhinagar Thermal Power Station (GTPS).
In this paper, a detailed energy study is shown for 210MW, Unit-4 of coal fired thermal power plant at
Gandhinagar Thermal Power Station (GTPS) to evaluate the plant and subsystem{feed water heaters(high
pressure and low pressure),etc} efficiencies. The boiler efficiency is calculated using indirect method after
estimating the various heat losses in the boilers. It highlights the positive features of this power plant as well as
brings out areas where further detailing and corrective measures are required for efficient utilization of the
sources available in the plant. Energy analysis is used to evaluate the overall thermal efficiency of the plant by
computing the individual efficiency of the boiler (86.84%), steam turbine (43.5%), and generator (98%). The
overall efficiency of the plant (Unit-4) appears to be 37.01%.
KEY WORDS: Power generating plant, boiler, steam turbine, first law analysis.

1. INTRODUCTION

thermodynamic losses, thereby improving the

Power consumption per capital indicates the

energy efficiencies of the system. Energy like

industrial and economical growth of the

many other commodities should be evaluated

country and thereby represents the living

and the conventional energy analysis, based on

standard of the people of the same. The whole

the first law of thermodynamics, evaluates

world is in grip of electrical energy crisis and

energy mainly on the quality.

pollution due to the power plants. The overall

Very careful analysis of the problem and

power scene in India shows heavy shortages in

proper planning and execution is necessary to

almost all the states. The government of India

solve the power crisis in India. So in this

has advocated Energy for all by the year

paper, a detailed energy study is shown for

2012. Even though the Indian power sector is

210MW, Unit-4 of coal fired thermal power

at the forth place of the power production in

plant at Gandhinagar Thermal Power Station

the world. The significant role of thermal

(GTPS)

power station in Indias power generation

subsystem{feed water heaters(high pressure

scenario can be gauged from the truth that they

and low pressure),etc} efficiencies. The first

supply about 66% of the total installed

law analysis is used to assess the overall plant

capacity. Some of the available options are to

performance. In operation and maintenance of

evaluate overall and individual component

a power plant, the feed water heaters are

efficiencies

practically neglected compared with other

and

to

identify and

assess

IJAET/Vol.I/ Issue III/Oct.-Dec.,2010/1-12

to

evaluate

the

plant

and

International Journal of Advanced Engineering Technology

E-ISSN 0976-3945

components. Efficient and reliable service

saving

from feed water heaters requires more care in

economiser, air preheater, reheaters, steam

both operations and maintenance than care that

traps etc. which effect on overall efficiency of

has been taken for nay other components of

coal or oil fired thermal power plants. The

power plant.

equipment for firing of fuel into furnace and

1.1 Literature Review

handling of fuel and ash are other important

Power plant is an assembly of a system, where

aspects of plant study. One should also focus

electricity is being generated by using

on

different mechanical and electrical equipment

condensing exhausting steam, water treatment,

and different processes. The basic components

water cooling, dust removal, Draft control, etc.

of the plants are steam generator {Steam

In Nuclear stations heat is produce in a reactor

generator is a complex integration of boiler

which replaces the convectional boiler.

along-with accessories (furnace, super heater,

1.3 Classification of steam generator or

re-heater, boiler, economizer & air pre-heater

boiler

etc.) and various auxiliaries such as pulverizer,

Classification of steam generator or boilers

burners, fans, stokers, dust collector and

can be made in different ways. From the point

precipitators,

of view of application, they can be;

ash-handling

equipment

&

devices

auxiliary

such

as

equipments

super-heaters,

and

need

of

chimney.}, steam turbine, steam condenser

a) Utility steam generator ,b) Industrial steam

and feed water pump.

generator, c)Marine steam generator.

1.2 The Principle types of Power Plants

1.3.1 Utility steam generator

The Principle types of Power Plants are as

Utility steam generator is those used by

below:

utilities for electric-power generating plants.

1. Steam Plants using coal, oil or nuclear

fission.

Depending on whether the pressure of steam is

below or above the critical pressure (221.2

2. Internal combustion engine Plant.

bar), that can be either subcritical or

3. Gas turbine Plant.

supercritical units. The subcritical steam

4. Hydroelectric Plant.

generators are water tube drum type and they

In steam power plant coal or oil is used as a

usually operate at between 130-180bar steam

fuel for generation of high pressure and high

pressure. The supercritical steam generators

temperature steam. In the boilers / the steam

are drum less once-through tube and operate at

generators steam is produced and then utilised

240 bar pressure. Majority of the utility steam

to drive the steam turbines which are coupled

generators are of the 170-180 bar water tube-

to generator to get electricity. The furnace may

drum variety, which produce superheated at

employee

about 540-5800C with one or two stages of

grate

burning

of

solid

fuel,

pulverised fuel in burner or furnace oil in oil

reheating.

burners. The Plant may content server with

1.3.2 Industrial steam generators

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International Journal of Advanced Engineering Technology

E-ISSN 0976-3945

Industrial steam generators are those used in

Type and cost of the land, availability of fuel,

process industries like sugar, paper, and jute

transportation facility, service water facility,

and so on, and institution like hospital,

availability of staff, near to the load centre, ash

commercial

disposal facility, away from residential area.

and

residential

building

complexes. They are smaller in size. They

2. About Gandhinagar Power Plant

operate pressures ranging 5 to 105 bar with

Gujarat State Electricity Corporation Limited

steam capacities up to 125 kg/s.

(GSECL) was incorporated in August 1993

1.3.3 Marine steam generators

and is registered under the Companies Act,

Marine steam generators are used in many

1956 with the objectives to initiate a process

marine ships and ocean liners driven by steam

of restructuring of Power Sector and to

turbines. They are usually oil-fire. They

mobilize resources from the market for adding

produce superheated steam at about 60-65 bar

to the generating capacity of the State and

and 540 C.

improving the quality and cost of existing

1.3 About power plant

generation. The Company was promoted by

The Rankine cycle is the basic cycle for

erstwhile Gujarat Electricity Board (GEB) as it

operation of steam power plant. Thermal

is wholly owned subsidiary in the context of

power station means a factory for conversion

liberalization and as a part of efforts towards

of chemical energy of fuel into electrical

restructuring of the Power Sector. The

energy. Coal fired units produce electricity by

operations of GSECL were limited to Power

the burning coal in a boiler to heat water to

Stations units Gandhinagar Thermal Power

produce steam. The steam, at tremendous

Station, Wanakbori Thermal Power Station,

pressure, flow into a turbine, which rotates

Utran GBPS & Dhuvaran Combined Cycle

armature

Power

of

generator

to

produce

the

Plant

(CCPP)

till

the

complete

electricity. The steam is condensate and

unbundling of erstwhile GEB was undertaken

converted back into water, and the returned to

upto 31st March 2005. The Gandhinagar

the boiler to complete the closed cycle.

Thermal

The basic requirements of thermal power plant

Gandhinagar, the capital of Gujarat near

are:

Ahmedabad.

Raw

material

should

be

Power

Station

is

located

at

It is a Coal Based Power

available

Station. It is on the bank of Sabarmati River.

continuously, generated energy should be

There are two units of 120 MW each (Unit no.

utilized properly and qualified staff should be

1 & 2), three units of 210 MW each (Unit no.

available as per requirement and proper

3, 4 & 5) with a total installed capacity of 870

provision of removal of ash and other by-

MW. All the above units are of BHEL make.

products during power generation.

Commissioning dates of unit no. 1 to 5 are

Basic points to be considered during site

13.03.1977,

selection are as follows:

20.07.1991 and 17.03.1998 respectively.

IJAET/Vol.I/ Issue III/Oct.-Dec.,2010/1-12

10.04.1977,

20.03.1990,

International Journal of Advanced Engineering Technology

E-ISSN 0976-3945

Based on the data available in table 1, table 2

Boiler

and table 3 for Gandhinagar Thermal Power

efficiency, and d) Effectiveness of heaters.

losses

calculations,

c)

Turbine

Station, we have done a) Energy analysis, b)

Table 1: Boiler Specifications
Particular

Unit-3 &4
Design
value

Unit-5
Design value

Actual value

Unit-3
Unit-4
210
150
180
Radiant Reheat, Natural

Load(MW)
Type

Actual
value

210
210
Radiant Reheat, Natural

Circulation,

Circulation,

690

480

520

690

662

247

165

232

245.6

241

SH

155

135

153

155

147.3

RH

38.1

26

33

36.11

34.14

SH

540

540

540

540

541

RH

540

530

540

540

542

Capacity(T/hr)
Feed water temp(0C)
2

Steam at boiler outlet(Kg/cm )

Steam temp at Boiler outlet(0C)

coal

Fuel used
85.77

Efficiency (%)

coal

82.91

81.79

85.77

81.83

Table 2: Turbine specification

Particular

Unit-3 &4
Design

Unit-5
Design

Actual value

value

Unit-3

value

Unit-4

2x 210MW

Capacity(MW)

480

Actual value

1x 210MW

No. of stages of cylinder

690

520

690

HP turbine

25

25

IP turbine

20+20

20+20

LP turbine

8+8

8+8

662

600 to 300

Critical Speed
0

Exhaust temp( C)

45-55

54

52

44-57

40.2

Efficiency

43.24

37.22

47.71

43.24

41.37

Table 3: Coal specification

Particular
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Unit-3 &4

Unit-5

International Journal of Advanced Engineering Technology

Actual value

Design
value

Unit-3

E-ISSN 0976-3945

Design

Actual value

value

Unit-4

Type

Bituminous

Bituminous

Caloric value(Kcal/Kg)

3800

3000

Ash content (%)

35

42

Volatile matter (%)

23

23

Sulphur content (%)

0.5

139.5

Quality required (MT/hr)

94.63

109.5

177

300000

Storage capacity (MT)

125.77
222003

3. Result analysis and discussion

Using these data and compiled value, First law

Energy is conserved in every device or process

analysis (energy analysis) is carried out for the

i.e. in balance; it can be neither produced nor

given thermal power plant.

consumed.

Energy entering with fuel,

The performance of a plant is evaluated by

electricity, flowing streams of matter, and so

calculating the overall efficiency of unit by

on can be accounted for in the products and by

using the individual efficiencies of boiler,

products. Energy cannot be destroyed. Energy

turbine and generator.

analysis is based on the first law of

The 210 MW units taken for analysis is to

thermodynamics and it is the measured of

consider being having the following system:

quality only.

SYSTEM 1

Boiler system.

The data for boiler operation and turbine

SYSTEM 2

Steam cycle.

operation of unit-4 of GTPS at full load were

SYSTEM 3

Cooling water system.

observed and relevant parameters have been

SYSTEM 1 (Boiler system) consists of the

estimated.

following components and is shown in

figure1; Combustor, Heat exchangers.

Figure 1 Folw of fluids on boiler

SYSTEM 2 (Steam cycle) consists of the

figure2; Turbine, Condenser(C), Feed Water

following components and is shown in

Heater (FWH), Pump (P)

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E-ISSN 0976-3945

SYSTEM 3 (Cooling Water System) consists

losses due to incomplete combustion Energy

of the following components; Circulating

losses due to moisture in fuel ,Energy losses

water pumps, Fans.

due to hydrogen in fuel , Energy losses due to

The performance of a plant is evaluated by

moisture coming with air supplied ,Energy

calculating the individual efficiencies of the

losses due to ash and slag, Energy losses due

boiler, turbine and generator. The efficiency of

to radiation loss.

the boiler is evaluated by indirect method. In

The boiler efficiency is calculated, using the

the indirect method the input is assumed to be

indirect method after estimating the various

100% and the various losses encountered in

heat losses in the boiler. Table 4 represent the

the boiler are calculated and subtracted from

reading taken for the boiler and coal mill.

100. The various losses in the boiler are;

Based on the data available in table 4 , the

Energy losses due to the exhaust gases ,

calculations are made for boiler losses and the

Energy losses due to unburn carbon ,Energy

results are shown in table 5.

Figure 2: Steam cycle

Figure 3: Energy Balance of Steam Generator

Table 4: Data for boiler and coal mills

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International Journal of Advanced Engineering Technology

E-ISSN 0976-3945

Content

Unit

Value

Load

MW

210.36

Coal flow rate

T/hr

140.35

Steam flow rate

T/hr

593.37

232

Mill power

KW

900

Total air flow

T/hr

690.2

Relative humidity

60.42

Absolute humidity (Kg water/kg dry air)

Kg

0.0195

FW inlet temp.
Mills

Dry bulb temp.

30

Wet bulb temp.

27

FD fan discharge temp

37.9

APH inlet gas temp

299

APH outlet gas temp

157.9

Oxygen in APH inlet

Oxygen in APH outlet

4.3

CO2 in APH inlet

14.8

CO2 in APH outlet

14.5

Nitrogen in APH inlet

14.5

Combustibles in bottom ash

6.6

Combustibles in fly ash

0.7

C
C
C
C

Table 5: Result obtained for boiler and coal mills

Types of losses

KJ/kg

Energy losses due to the exhaust gas(Q2)

2501.1

5.29

Energy losses due to unburn carbon(Q3)

250.98

0.52

Energy losses due to incomplete combustion. (Q4)

2209.2

4.64

Energy losses due to moisture in fuel. (Q5)

237.80

0.40

Energy losses due to hydrogen in fuel. (Q6)

143.0

0.29

Energy losses due to moisture coming with air supplied. (Q7)

601.48

1.21

Energy losses due to ash and slag. (Q8)

384.65

0.81

Total losses 6328.21

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13.16

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5.29
4.64

5
4
3
2

1.21
0.81

0.52

0.4

0.29

0
Q2

Q3

Q4

Q5

Q6

Q7

Q8

Chart 1 Energy Balance of Steam Generator

From the chart1, it is clear that losses Energy

incomplete combustion, which is 3.4%. The

losses due to the exhaust gas are more

lowest losses occur in boiler due to moisture in

compared to all boiler losses. Which is

air, which is 0.14%. Due to these energy losses

5.2%.the next highest is losses due to

boiler efficiency is decrease 13.16%.

Table no 6 represent the data available for the turbine.

Content

Parameter

Unit

Reading

MW

210.36

Turbine inlet steam flow

MS

T/hr

593.37

Super heater steam pressure

PSH

Kg /cm2

149.36

Load

Super heater steam temp.

TSH

532.92
2

Hot Re-heater steam pressure

PHRH

Kg /cm

35.09

Hot Re-heater steam temp

THRH

534.81

Cold Re-heater steam pressure

PCRH

Kg /cm2

34.81

Cold Re-heater steam temp

TCRH

335.45
2

Feed Water pressure before Economiser

PFW

Kg /cm

174.66

Feed Water temp. before Economiser

TFW

241.09

Enthalpy of super heater steam

HS

KJ/Kg

3549.97

Enthalpy of Hot Re-heater steam

HHRH

KJ/Kg

3561.4

Enthalpy of Cold Re-heater steam

HCRH

KJ/Kg

3104.1

Enthalpy of feed water

HFW

KJ/Kg

1009.4

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International Journal of Advanced Engineering Technology

E-ISSN 0976-3945

From the available data for the turbine,

Generator efficiency is taken as 98%

following calculations are made to calculate

So the overall efficiency

the turbine efficiency.

= (boiler efficiency X turbine efficiency X

Turbine inlet steam flow = 593.37 T/hr =

generator efficiency)

164.825 kg/s.

= (0.8684 X 0.435 X 0.98)

Heat input to turbine

= 37.01%

= {turbine inlet steam flow X (SH enthalpy-

Due to the turbine efficiency and boiler

FW enthalpy)} +{HRH steam flow X (HRH

efficiency, we get overall efficiency is

enthalpy CRH enthalpy)

37.01%. It is very low.

= {164.825 X (3549.97 1009.4)} + {140.1 X

Overall heat rate = (1 / overall efficiency)

(3561.4 3104.1)}

= 2.701 KJ/S

= 482817.18 KJ/Kg

The efficiency of the turbine is determined

Turbine efficiency = power generation/ heat

estimating the net heat input to turbine and

input to turbine= {210.36 X 10 / 482817.18}

electrical power plant from the generator in

= 43.5%

terms of heat values. Thus turbine efficiency

Superheater

temperature

532.92 C

and

obtained is 43.5%.

pressure 149.36 Kg/cm . That means that

The generator efficiency is taken as 98%.

quality of steam is rich. Reheater temperature

Then the overall efficiency is estimated as

534.81 C it is nearly superheater temperature

0

532.92 C so, we can say that reheater is good

0

condition. Feed water temperature is 241.09 C

37.01%.
The above results are shown in the table no 7
shown below:

it is nearby 250 C that is desirable. Due to

turbine losses, we get turbine efficiency is
very low which is 43.5%.
Table .7 Different efficiencies of power plant

Component

Efficiency (%)

Boiler

86.84%

Turbine

43.5%

Generator

98.0%

Overall efficiency

37.01%

Chart 2 Compression of Energy Efficiencies

Overall
efficiency,
37.01%
Boiler
, 86.84%
Generator,
98.00%
Turbine
, 43.50%

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International Journal of Advanced Engineering Technology

E-ISSN 0976-3945

Table 8: Represents the observation taken for the high pressure feed water heater (HPH)
cascaded backward and effectiveness of heaters to be found.
Contents

Unit

Load

MW

210.36

FW flow

t/hr

593.87

HPH 5 shell pressure

Kg/cm2

36

HPH 6 shell pressure

Kg/cm2

16

FW temperature HPH 5 IN

163.7

FW temperature HPH 5 OUT

200.7

FW temperature HPH 6 OUT

244

Enthalpy of drain water from HPH 5

KJ/Kg

2757

Enthalpy of drain water from HPH 5

KJ/Kg

2598.62

C
C
C

Figure 4 Flow diagram of HP Heater

Effectiveness of heater

KJ/Kg and 4131.17 KJ/Kg. That shows that

= (FW Temp rise)/ (Tsat temp TFW temp)

system is perfect. Effectiveness of the heater

Effectiveness of HPH6 = (243-200.7)/(244.2-

HPH6 and HPH5 is 0.97 and 0.98 that is

200.7) =0.97

nearly 100%. In general, the total losses =

Effectiveness of HPH5= (200.7 163.7) /

13.16% , Boiler efficiency = 100 13.26 =

(201.1 163.7) =0.98

86.84%, Turbine efficiency = 43.5% ,HP

Net heat grain to feed water and actual heat

heater effectiveness HPH5 and HPH6 are 0.98

gained by feed water is respectively 3600

and 0.97.

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CONCLUSION
From the energy analysis made for the unit-4,

providing sufficient data for plant. We are also

210MW of the GTPS the following

thankful to those who help directly or

conclusion are drawn:.

indirectly to complete the project

It is seen that boiler efficiency is

highest, which is 86.84% and the heat
losses are only 13.16%.

Out of all the boiler losses, the highest

heat losses 5.29% occurs due to the
exhaust gas.

The turbine efficiency is very less and

is estimated as 43.5% Because of the
several turbine losses like ; Losses in
regulating valve, Nozzle friction
losses , Blade friction losses , Disc
friction losses , Partial admission
losses , Gland leakage losses, Cary
over losses.

From the thermodynamic analysis

using first law of thermodynamics, we
can conclude that, energy analysis
evaluates the plant quantitatively. The
power plant overall efficiency is
37.01%.

The

effectiveness

of

HP

heater

working in good condition should

have an effectiveness of 0.85. The
performance of HPH6 and HPH5 are
in

good

conditions

as

their

effectiveness 0.97 and 0.98.

6. ACKNOWLEDGMENTS
We are very much thankful to peoples of
Gandhinagar

thermal

power

plant

IJAET/Vol.I/ Issue III/Oct.-Dec.,2010/1-12

for

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