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SUMMER TRAINING
REPORT
JUL-AUG-2010
Submitted by
PrIyanshu dIxIt
Roll.No - 0715340073
SkylIne InstItute of EngIneerIng &
TecHnology, Greater noIda
CONTACT No.- 9 7 1 8 2 2 1 7 2 9
CERTIFICATE
( )
( )
ACKNOWLEDGEMENTS
I will like to express my gratitude to the following people for their help in
the work leading to this report:
IntroductIon
IPGCL-PPCL
Indraprastha Power Generation Co. Ltd. (IPGCL) was incorporated on 1st July,2002
and it took over the generation activities w.e.f. 1st July,2002 from erstwhile Delhi Vidyut
Board after its unbundling into six successor companies. The main functions of IPGCL is
generation of electricity and its total installed capacity is 994.5 MW including of Pragati
Power Station. Its associate Company is Pragati Power Corporation Limited which was
incorporated on 9th January, 2001.
To bridge the gap between demand and supply and to give reliable supply to the capital City
a 330 MW combined cycle Gas Turbine Power Project was set up on fast track basis. This
plant consists of two gas based Units of 104 MW each and one Waste heat Recovery Unit of
122 MW. Gas supply has been tied up with GAIL through HBJ Pipeline. Due to paucity of
water this plant was designed to operate on treated sewage water which is being supplied
from Sen nursing Home and Delhi Gate Sewage Treatment plants.
Their Vision:
The Power demand in the Capital City is increasing with the growth of
population as well as living standard and commercialization. The
unrestricted power demand in the summer of year 2000 was 3000 MW
and increasing every year @ 6 to 7%. In 2005-2006, it is expected to be
4078 MW and by 2009-10 it will reach 5075 MW.
Erstwhile DVB's own generation from RPH, I.P. Station and Gas Turbine
Power Station had been around 350-400 MW and Badarpur has been
supplying 600-700 MW and the balance was met from the Northern Grid
and other sources.
To bridge the gap between demand and supply and to give reliable supply
to the Capital City, Delhi Govt. had set up 330 MW Pragati Power Project
on fast track basis. To cut down the project cycle duration, turnkey
contract was awarded to M/s BHEL in May 2000 based on similar project
executed by BHEL at Kayamkulam (owned by NTPC). To further ensure
reliable and smooth operation of the plant, experience of NTPC was
utilized by retaining them as engineering consultant and specification of
the Kayamkulam Project were adopted.
The total capacity of this Station is 270 MW. The gas supply has been tied
up with GAIL through HBJ Pipeline. The APM gas allocation was not
sufficient for maximum generation from the power station. Subsequently
with the availability of Regassified -LNG an agreement was made with
GAIL in Jan. 2004 for supply of R-LNG so that optimum generation could be
achieved. The performance of the station has improved from 49 % in
2002-03 to 70.76 % in 2005-06.
Steam TurbIne
• Rankine cycle
• Reheat cycle
• Regenerative cycle
• Combined cycle
to the casing and one set of rotating blades is connected to the shaft. The
sets intermesh with certain minimum clearances, with the size and
configuration of sets varying to efficiently exploit the expansion of steam
at each stage.
TurbIne EffIcIency
Impulse TurbInes
this higher exit velocity is commonly called the "carry over velocity" or
"leaving loss".
ReactIon TurbInes
In the reaction turbine, the rotor blades themselves are arranged to form
convergent nozzles. This type of turbine makes use of the reaction force
produced as the steam accelerates through the nozzles formed by the
rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It
leaves the stator as a jet that fills the entire circumference of the rotor.
The steam then changes direction and increases its speed relative to the
speed of the blades. A pressure drop occurs across both the stator and the
rotor, with steam accelerating through the stator and decelerating
through the rotor, with no net change in steam velocity across the stage
but with a decrease in both pressure and temperature, reflecting the work
performed in the driving the rotor.
When warming up a steam turbine for use, the main steam stop
valves (after the boiler) have a bypass line to allow superheated steam to
slowly bypass the valve and proceed to heat up the lines in the system
along with the steam turbine. Also a turning gear is engaged when there
is no steam to the turbine to slowly rotate the turbine to ensure even
heating to prevent uneven expansion. After first rotating the turbine by
the turning gear, allowing time for the rotor to assume a straight plane
(no bowing), then the turning gear is disengaged and steam is admitted to
the turbine, first to the astern blades then to the ahead blades slowly
rotating the turbine at 10 to 15 RPM to slowly warm the turbine.
thrust bearing for the turbine shaft. To prevent this, along with controls
and baffles in the boilers to ensure high quality steam, condensate drains
are installed in the steam piping leading to the turbine.
Speed regulatIon
Gas TurbIne
As a general rule, the smaller the engine the higher the rotation rate
of the shaft(s) needs to be to maintain top speed. Turbine blade top speed
determines the maximum pressure that can be gained, this produces the
maximum power possible independent of the size of the engine. Jet
engines operate around 10,000 rpm and micro turbines around
100,000 rpm.
Systems which are designed for maximum efficiency in which the hot exhaust gases
from the gas turbine are used to raise steam to power a steam turbine with both turbines being
connected to electricity generators.
To minimise the size and weight of the turbine for a given output power, the output
per pound of airflow should be maximised. This is obtained by maximising the air flow
through the turbine which in turn depends on maximising the pressure ratio between the air
inlet and exhaust outlet.
System Efficiency: Thermal efficiency is important because it directly affects the fuel
consumption and operating costs.
Combined Cycle Turbines It is however possible to recover energy from the waste heat of
simple cycle systems by using the exhaust gases in a hybrid system to raise steam to drive a
steam turbine electricity generating set. In such cases the exhaust temperature may be
reduced to as low as 140°C enabling efficiencies of up to 60% to be achieved in combined
cycle systems.
Thus simple cycle efficiency is achieved with high pressure ratios. Combined cycle
efficiency is obtained with more modest pressure ratios and greater firing temperatures.
Fuels One further advantage of gas turbines is their fuel flexibility. Crude and other heavy
oils and can also be used to fuel gas turbines if they are first heated to reduce their viscosity
to a level suitable for burning in the turbine combustion chambers.
MechanIcal EquIpments:
Superheater Section: The Superheater Section of the HRSG is used to dry the
saturated vapour being separated in the steam drum. In some units it may only be
heated to little above the saturation point where in other units it may be superheated
to a significant temperature for additional energy storage. The Superheater Section
is normally located in the hotter gas stream, in front of the evaporator.
The steam turbine-driven generators have auxiliary systems enabling them to work
satisfactorily and safely. The steam turbine generator being rotating equipment generally has
a heavy, large diameter shaft. The shaft therefore requires not only supports but also has to be
kept in position while running. To minimize the frictional resistance to the rotation, the shaft
has a number of bearings. The bearing shells, in which the shaft rotates, are lined with a low
friction material like Babbitt metal. Oil lubrication is provided to further reduce the friction
between shaft and bearing surface and to limit the heat generated.
Condenser
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. Such
condensers use steam ejectors or rotary motor-driven exhausters for continuous removal of
air and gases from the steam side to maintain vacuum
For best efficiency, the temperature in the condenser must be kept as low as practical
in order to achieve the lowest possible pressure in the condensing steam. Since the condenser
ο
temperature can almost always be kept significantly below 100 C where the vapour pressure
of water is much less than atmospheric pressure, the condenser generally works under
vacuum. Thus leaks of non-condensable air into the closed loop must be prevented. Plants
operating in hot climates may have to reduce output if their source of condenser cooling
water becomes warmer; unfortunately this usually coincides with periods of high electrical
demand for air conditioning. The condenser uses either circulating cooling water from a
cooling tower to reject waste heat to the atmosphere, or once-through water from a river.
Figure 8: A Typical Water Cooled Condenser
Figure 9: Showing Exclusive Inside View of Tube Type Condenser Installed at IPGCL Gas Turbine Station
Deaerator
A steam generating boiler requires that the boiler feed water should be devoid of air
and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the
metal. Generally, power stations use a deaerator to provide for the removal of air and other
dissolved gases from the boiler feedwater. A
deaerator typically includes a vertical, domed
deaeration section mounted on top of a
horizontal cylindrical vessel which serves as the
deaerated boiler feedwater storage tank.
CoolIng Towers
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove process heat
and cool the working fluid to near the wet-bulb air temperature or rely solely on air to cool
the working fluid to near the dry-bulb air temperature. Common applications include cooling
the circulating water used in oil refineries,
chemical plants, power stations and
building cooling. The towers vary in size
from small roof-top units to very large
hyperboloid structures (as in Image 1) that
can be up to 200 metres tall and 100 metres
in diameter, or rectangular structures (as in
Image 2) that can be over 40 metres tall and
80 metres long. Smaller towers are
normally factory-built, while larger ones are
constructed on site.
Figure 11: Fan of Induction Type Cooling Tower
Figure13: Inside Views of Cooling Tower Left Hand and Right Hand Respectively.
AUXILIARY SYSTEMS
All large generators require auxiliary systems to handle such things as lubricating oil
for the rotor bearings, hydrogen cooling apparatus, hydrogen sealing oil, de-mineralized
water for stator winding cooling, and excitation systems for field-current application. Not all
generators require all these systems and the requirement depends on the size and nature of the
machine. For instance, air cooled turbo generators do not require hydrogen for cooling and
therefore no sealing oil as well. On the other hand, large generators with high outputs,
generally above 400 MVA, have water-cooled stator windings, hydrogen for cooling the
stator core and rotor, seal oil to contain the hydrogen cooling gas under high pressure,
lubricating oil for the bearings, and of course, an excitation system for field current. There are
five major auxiliary systems that may be used in a generator. They are given as follows:
The plate pattern is fitted at a position on the rotor section close to where
the shaft fits in to the bearing pedestal - this location allows
straightforward access to the plate pattern through the bearing cover. The
turbine casing and pedestal are mechanically joined in most
circumstances, where the pedestal and casing movement is catered for
with a sliding base arrangement. At the HP, IP and LP3 locations a bracket
assembly fitted to the pedestal cover accepts a standard inductive
proximity probe to generate the timing waveforms.
Capacity : 34 MW
No. of stages : 50
Steam flow : 125 Tonne/hr.
Inlet temperature : 502°C
Inlet pressure : 40 Kg/cm2
Lube oil grade : SP 46
No. of journal bearings : 5
No. of thrust bearing : 1
Coupled Main Oil Pump (MOP) with turbine shaft
Exhaust steam pressure : 3.3 ata
Exhaust steam flow : 2.16 Tonne/hr.
Exhaust pressure : 0.105 Kg/cm2
Lube oil pressure : 9 Kg/cm2
Over speed trip : >3300 rpm
Differential expansion : +6 to -4
\
Gas TurbIne SpecIfIcatIons
Capacity : 30 MW
Gas pressure : 20 Kg/cm2
Speed : 5135 rpm
Generator speed : 3000 rpm
Generation at : 11 KV
Exhaust temperature : 560°C
Air flow : 490 Tonne/hr.
DIESEL ENGINE
1. Vibration on bearings.
2. Lube oil header temperature.
3. Lube oil header pressure.
4. Hydraulic oil pressure.
5. Hydraulic trip oil pressure.
6. Battery charger should be healthy. Battery voltage should >120V
7. Cooling water pressure.
8. Air sealing system.
9. TAD should < 170 mm.
10. GAD should < 150 mm.