REPORT ON SUMMER TRAINING AT NTPC FARIDABAD

ACKNOWLEDGEMENT
I am thankful to NTPC for providing me an opportunity to get an insight and practical experience in the operation, electrical grid system, control and maintenance of power plant.

ACKNOWLEDGEMENT

I am extremely grateful to Mr. R.K. Niranjan (HRD-EDC) under whose guidance this summer training was conducted successfully. I feel highly indebted to all the senior NTPC officials who extended me a constructive help in the technical field. I am thankful to Mr K.K Sharma (Sr. Manager-Chemistry) Mrs. Prachi (Electrical maintenance) Mr N.N Mishra (AGM- O&M) Mr Manoj Agarwal (DGM- Mechanical maintenance) Mr Jimmy Joseph (S.S- C&I) Mr D.C Tiwari (S.S- Operation)

I gratefully acknowledge all the engineers/staff who gave us their valuable time, encouragement, constructive criticism for familiarizing us with all technical aspects of the power plant.

Submitted Sandeep Tewatia Mr. R.K Niranjan 3rd year (HRD-EDE) engineering college of engineering -131001

To

B-tech Electrical Hindu Sonepat

Contents

1. Overview of the Faridabad gas power station 2. Combined cycle power generation 3. Overview of the power plant
a) gas turbine system b) Heat recovery steam generator c) Steam turbine system d) Condensate e) Feed water system 4. Electrical systems 5. Mechanical systems a) Gas turbine and auxillaries b) Heat recovery steam generator c) Steam turbine system and auxillaries d) Condenser and auxillaries e) Steam cycle charactersticks f) Feed water system auxillaries

6. Control and Instrumentation

Overview of the Faridabad Gas Power Station

(i)

Location

: Faridabad GPP is located near village Mujhedi & Neemka in Faridabad district of Haryana State. The Latitude & longitude of the site are 280 20 48 (N) & 770 2148 (E) respectively. : 321.45 acres of land has been acquired (241.53 of Plant & 79.92 for Township) : 431.586 MW (GT: 2X137.758 MW + ST 1X156.07 MW)

(ii)

Land Requirement

(iii)

Plant Capacity

(iv) (v)

Mode of operation Fuel

: Base Load : Natural Gas (Main Fuel) Naphtha (Alternate Fuel)

(vi) (vii)

Gas requirement Gas transportation

: Average 1.58 mcmd at 68.5% PLF 2.30 mcmd at 100% PLF. : To be piped from HBJ pipeline by GAIL. : Closed cycle cooling water system with Induced draft cooling towers and make up water supply from high level canal fed by tubewell operated by Haryana State Minor Irrigation Tubewell Corporation & Rampur Distributory of Gurgaon canal. : Transmission System being built by Power Grid. : Haryana State

(viii) CW System

(ix) (x) (xi)

Power Evacuation Beneficiary State

Project Cost (Power : Rs. 1163.60 crore Plant & Facilities)

(xii)

Cost of Generation

: 205.82 paise / kwh : : Liquid Effluents from plant and township will be neutralized before disposal. : Emission of NOx will be limited within 50 ppm during operation of the plant with natural gas as stipulated in the Environmental clearance by MOEF. : The project is being partly financed by Govt. of India in the form of loan and equity. The fund from GOI is being provided by JBIC, Japan to an extent of 22171 million Yen. Balance fund requirement will be met from internal resources & Domestic Commercial Borrowings (DCB). : GT#1 1999 GT#2 ST Govt. App. Sch. Jan 2000 Mar 2000 Jan 2001 Actual June Oct. 1999 July 2000

(xiii) Environmental Aspects Water Pollution

Air Pollution

(xiv) Project Financing

(xvi) Commissioning Schedule

Combined cycle power generation

COMBINED CYCLE In combined/closed cycle, two combustion turbine-generators operate in conjunction with two heat-recovery steam generators and a steam turbine-generator. In the first cycle, fuel is burned and the resulting combustion gases power two turbinegenerators to produce electricity. Hot exhaust normally lost during this process is captured and routed through the two heat-recovery steam generators. These units boil water to create steam, which spins an additional turbine-generator and produces more electricity. Finally, the steam is discharged into a condenser, which returns the steam to its liquid state for recycling.

At FGPS, the gas turbines installed are based on the Brayton Cycle while the steam turbine is based on Rankine Cycle. These cycles are explained below. BRAYTON CYCLE Gas turbines operate on this cycle. In this cycle air is compressed in a compressor. This compressed air is used for combustion and the combustion product is allowed to expand in the turbine, which is coupled with the generator. In modern gas turbines the temperature of the exhaust gases is in the range 500C to 580C.

RANKINE CYCLE The conversion of heat energy to mechanical energy with the aid of steam is carried out through this cycle, which involves:

 The initial state of the working fluid is water, which at certain temperature is compressed by the pump and fed to the boiler. In the boiler the compressed water is heated at constant pressure. Superheated steam is expanded in the turbine, which is coupled with the generator.

COMBINING TWO CYCLES TO IMPROVE EFFICIENCY We have seen in the above two cycles that the gas turbine exhaust is of 500C-580C and in the Rankine cycle temperature required to generate is 500C-560C. So we use the gas turbine exhaust to generate steam in the Rankine cycle and save fuel required to heat the water.

ADVANTAGE OF THE COMBINED CYCLE PLANTS Apart from the higher efficiency, the combined cycle power plants have following advantages: Low installation cost Low gestation period Better reliability Low environmental pollution

If efficiency of gas turbine cycle (where natural gas is used as fuel) is 31% (which is usually the case) and the efficiency of Rankine cycle is 35%, then over all efficiency comes to 49%.

Overview of the power plant

Plant overview presents a broad picture on how the fuel is utilized to generate power without going much in detail. It shows how the different units of a power plant work in tandem to form a complex but highly organized system, which is efficient and very reliable.

Gas turbine system The gas turbine is a common form of heat engine working with a series of processes consisting of compression of air taken from atmosphere, increase of working medium temperature by constant pressure ignition of fuel in combustion chamber, expansion of SI and Internal Combustion (IC) engines in working medium and combustion, but it is like steam turbine in its aspect of the steady flow of the working medium.

For the gas turbine to produce any work, the hot gases must expand from a high pressure to a low pressure. Therefore the gases must first be compressed. If after the compression the fluid were expanded through the turbine, the power produced would equal that used by the

compressor, provided functioned ideally.

that

both

the

turbine

and

compressor

If heat were added to the fluid before it reached turbine, raising its temperature, then an increase in power output could be achieved. If more and more thermal energy could be added to the fluid then more and more power output could be produced. Unfortunately this cannot occur as the turbine blades have metallurgical thermal limit. If the gases continuously enter at a temperature higher than this, the combined thermal and material stresses in the blades will cause them to fail. Typically, inlet temperature of 1300K may be found in industrial turbines and inlet temperatures in experimental models are up to 1500K.

At P.P.C.L two gas turbines, Model 9E of make General Electric (GT1) and Bharat Heavy Electrical Ltd. (GT2) are being used. The 9E is a simple flow cycle, single shaft gas turbine with fourteen reverse-flow combustion systems. The 9E assembly consists of six major section or groups: 1. 2. 3. 4. 5. 6. Air inlet. Compressor. Combustion system. Turbine. Exhaust. Support systems.

1. GAS PATH DESCRIPTION When the turbine starting system is actuated and the clutch is engaged, ambient air is drawn through air inlet plenum assembly, which is then filtered & compressed in the 17stage, axial flow compressor. Then this compressed air from compressor flow into the annular space surrounding the 14combustion chambers. From there, it flows into the combustion liners for proper fuel combustion.

Fuel for combustion is being supplied by Gail (Gas Authority of India Ltd.) through HBJ (Hazirapur-Bijapur-Jagdishpur) gas line at a pressure of 24Kg at 26oC.

This fuel is filtered for the removal of solid particles at the Gas Conditioning Skid before being fed into 14 equal flow lines each terminating at a fuel nozzle centered in the end plate of a separate combustion chamber. Prior to being distributed to the nozzles the fuel is accurately controlled to provide an equal flow into the 14 nozzle feed lines at a rate consistent with the speed and the load requirements of the gas turbine. The nozzle introduces the fuel into the combustion chamber where it is mixed with the combustion air. This fuel air mixture is then ignited in one of the 14-chambers and the flame thus produced is propagated to ignite other fuel chambers through connecting cross-fire tubes. After the turbine rotor approximates operating speed, combustion chamber pressure causes the spark plugs to retract so as to remove their electrodes from the hot flame zone. The hot gasses from the combustion chambers expand into 14 separate transition pieces attached to the aft end of the combustion chamber liners & flow from there to three-stage Turbine Section. Each stage consists of a row of fixed nozzles followed by a row of routable turbine buckets. In each nozzle row, the kinetic energy of the jet increases while the pressure drops & each following row of moving buckets, a portion of kinetic energy of jet turns the turbine rotor. Since the turbine is coupled to the generator rotor, the resulting rotation of turbine is transferred to generator, which generates the electrical power.

After passing the third stage buckets, the exhaust gasses (at about 570oC) are directed to the HRSG before being directed into exhaust hood (at about 140oC). The exhaust hood contains a series of turning vanes to turn the gasses from an axial direction to radial direction to minimize the exhaust hood losses. The gasses are then passed into the exhaust plenum & are expelled into atmosphere through the exhaust stack.

Heat recovery steam generator The Heat Recovery Steam Generator (HRSG) is installed so as to increase the overall efficiency of the plant. It works by using the utilizing flue gases of the gas turbine instead of burning fuel to produce steam which runs a steam turbine which has a generator coupled with it to produce electric power. With HRSG, the efficiency of the plant may be in excess of 48%.

The HRSG, installed at FGPS, is a horizontal, natural circulation, single drum, dual pressure, unfired, water-tube boiler. It is designed to generate steam quantities 190 T/hr for the HP drum and 40 T/hr for the LP drum. The feed water temperature is approximately 275 degree Celsius for the HP drum while for the LP drum, it is, 150.1 C at the designed point.

The gas turbine flue gases act as the heat source of the boiler. The combustion products heat water in a boiler where it is converted to steam. This steam drives the steam turbine, which is mechanically coupled, to a generator. The modern large sized boilers are of water-tube type design. In these boilers, water flows inside the tubes and the hot flue gases flow outside of them. The circulation of water through the tubes of the boiler is forced circulation through the action of pumps.
Flue gas flow

Flue gases from the exhaust of the Gas turbine are at the temperature of 540 degree Celsius and are generally at very high velocity. Therefore the fluegases are passed through a diffuser where pressure increases at the expanse of the velocity. Next the flue gases are allowed to pass through diverter damper gates, which permit the flow of gases out of the bypass chimney or towards the HRSG depending upon the position of the gate. The flue gases then rise along the height of the HRSG and are evenly distributed using mechanical barriers like gas distribution screens for the horizontal flow of the flue gases along the HRSG. The flue gases generally carry smoke, which deposit on the water tube as soot and reduce the heat transfer and

hence HRSG is provided with soot blowers namely FRSB full retractable soot blowers and HRSBs as per requirements.

Salient Features and Operation The boiler is divided into nine zones. In order of higher temperature, they are as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. HP Super heater-II HP Super heater HP Evaporator HP Economizer II LP Super heater LP Evaporator HP Economizer I LP economiser Condensate preheater (CPH)

Feedwater at BFP discharge is then pumped separately via HP BFP and LP BFP to the High Pressure (HP) and Low Pressure (LP) drums from which HP and LP steam is derived respectively. The cycle for both the HP and LP steam is basically the same. The water is first taken to the respective economizers to heat the water and then taken to the

evaporator where the water is converted to steam. This steam is further heated to produce superheated steam. This process takes place in the respective super heaters. Now, there is a possibility that the temperature of the HP steam becomes very high (more than the specifications) as there are two super heaters. To prevent the steam from attaining very high temperatures, a device called De-Super heater is installed between the two super heaters. It works by sprinkling water on the steam as the steam passes through it. This lowers down the temperature but also wets the steam. The steam is dried in the next superheated and hence the temperature of the steam is controlled. De-superheated is used only when required and the amount of water sprinkled is also controlled so as not to decrease the temperature of the steam too low that the second superheated cannot increase it to the optimum limit. This superheated steam is then taken to the turbine where it is allowed to expand and cool and do mechanical work on the turbine rotor. The expanded steam from the HP steam still has sufficient amount of heat and is taken to the LP turbine. The steam from the LP turbine is taken to the Condenser where it is converted back to water, as we cannot pump steam. The water is extracted from the condenser by the Condensate Extraction Pump (CEP). The water is extracted from the condenser as there is low pressure (vacuum, maintained by vacuum pumps) inside the condenser which has to be maintained otherwise there is a risk of back-flow of steam back to the turbine. So the difference in pressure has to be maintained and water has to be forced out. A part of the steam is also tapped to seal the turbine, which is cooled in the Gland Steam Cooler (GSC). The sealing is very critical as the difference in pressure is quite large between that inside the turbine and the outside. The steam has the tendency to escape and to prevent that we require the sealing. The water from the condenser and GSC is pumped together back to the condensate pre-heater and the cycle begins again. Everything in the plant works on a closed cycle to increase efficiency and maintain economical production. The de-mineralized water is produced after a long process involving dozing, filtering, reverse osmosis, ion exchangers, etc. which makes the water purification expensive. So, this water is not wasted and re-used. Only a small amount of make-up water is taken from the plant. The condensing

water (from LSP) in the condenser is cooled again and re-used to condense steam to water in the condenser.

Steam turbine system The turbine is a tandem compound machine with High Pressure (HP) and Low Pressure (LP) sections. The HP section is a stage flow turbine whereas the LP section is a double flow. Rigid couplings connect the individual turbine rotors and generator rotor. The HP turbine has been constructed for throttle control governing. The initial steam is admitted before the blading by two combined main steam stop and control valves. The steam from HP turbine exhaust is led to the LP turbine through cross-around pipes. Additional steam from LP stage of waste heat

recovery steam generator is passed to the LP turbine via twocombined LP stops and control valves.

HIGH PRESSURE (HP) TURBINE

The HP turbine is of single flow, double shell, construction with horizontally split casing. Allowance is made for thermal movement of the inner casing within the outer casing. The main steam enters the inner casing from top and bottom. The provision of an inner casing confines high steam inlet temperature and pressure conditions to the admission section of this casing, while the joint flange of the outer casing is subjected only to the lower pressure and temperature effective at the exhaust from the inner casing.

LOW PRESSURE (LP) TURBINE The casing of the double flow LP turbine is of three-shell design. The shells are of horizontally split-welded construction. The inner casing, which carries the first rows of stationary blades, is supported on the inner-outer casing so as to allow for thermal expansion. The innerouter casing rests at four points on longitudinal girders, independent of the outer casing. Three guide blade carriers, carrying the last guide blade rows are bolted to the inner-outer casing.

BLADING

The entire turbine is provided with reaction blading. The moving blades of the HP turbine and the initial rows of the LP turbine with inverted T-roots and integral shrouding are machined from solid rectangular bars. The last stages of the LP turbine consist of twisted, drop forged moving blades with fir-tree roots inserted in corresponding grooves of rotor. Like the moving blades, the HP stationary blades of HP turbine and the front rows of LP turbine are designed with integrally milled inverted Troots and shrouds. The last stages of LP turbine have guide blade rows of fabricated construction.

Condensate Steam after the extraction of work in the hp and lp turbines goes to condenser through flash box where the LP drain enters the condenser. Cooling water is supplied by the CW tubes where the water is pumped in by CW pumps. Water generally gets heated by 7-8 degree celcius. Steam from the LP exhaust gets condensed via indirect heating and is collected below in the HOTWELL. Very low pressure in the condenser is maintained by vacuum pumps. To make up for the water losses during the steam cycle, make up water is added to the condenser via DM water line. This DM water can be taken directly from the DM water line or through the Reserve Feed Tank. Water from the Hotwell is extracted by condensate extraction pumps (CEP). In this module two CEPs are provided while only one is operated while other is kept in standby mode. Water from the CEP discharge enters the Gland steam condenser (GSC) where it is heated by the gland steam via indirect heating. Gland steam condenses and is discharged back into the condenser. Heated water from the GSC is then taken to LPH and other feedwater systems. Condenser also receives the HP and LP bypass lanes from the turbines. The power-plant chemistry is constantly monitored via the specific conductivity and the PH level of the water in the condenser. Hotwell level is also important and is constantly controlled.

Cooling water system

The water in the coolant tubes of the condenser gets heated and is then taken to the cooling towers. Here the water gets sprinkled from the top of the specially designed cooling tower where the rising air from the bottom cools the water close to its wet bulb temperature. Thus temperature is lowered by 7-8 degree celcius. Unsaturated air of low relative humidity gets saturated in this process and leaves the cooling tower from the top. The suction of the air is provided by the induced draft fans provided at the tower top. Thus cooling tower is based on the forced draft cooling. Hence the height of the tower is quite low. Cooled water is discharged into the sump where the make up water is added as water loss occurs during the cooling through evaporation. Cooling water pumps get the suction from the sump and pump the water towards the condenser.

Feed water system

LP heater

Feed water from the GSC enters the LPH where the bled steam heats the feed water by indirect heating .LPH bypass lane is also provided to bypass the LP heater .
CPH and CPH RCP

The water from the LP heater goes to condensate preheater kept at the near exhaust of the HRSG. The flue gases before being discharged to the atmosphere are used to heat the feedwater. In this process the temperature of the flue gases falls down from 160 to 104 degree celcius. Generally this is above the saturation temperature of the SOX and the NOX gases in the chimney exhaust. When the natural gas is used the temperature is quite high and saturation temperature llimit is not reached however if the naptha is used then the flue gas temperature is lower by around 10 degree celcius hence the NOX gases could condense and form acidic products leading to cold end corrosion, if the CPH is used. Hence to overcome this recirculation pumps(RCPs) are switched on which pump the hot water at CPH discharge back to the CPH inlet thus considerably reducing the heat transfer and hence the flue gas temperature doesnt reduce to the saturation temperature limit.
Deaerator

Water from the CPH heater enters the the deaerator where the dissolved gases are removed from it. The steam from the LP superheater enters the deaerator from the bottom while the feedwater is sprinkled fron the top. The rising steam comes in direct contact of water thereby heating the water and the dissolved gases which as a result escape from the top along with some of the steam. The condence steam and the water are collected below in the storage tank. The storage tank is provided with the heating rod which is kept hot by the lp steam. The storage tank then separately discharges the feedwater to HP and LP BFP. The deaerator is generally kept at the height of 20 to 25 meters to keep the pressure head above the net positive suction head (NPSH) level of the water at thr BFP suction.

ELECTRICAL SYSTEMS The major electrical components used in the switchyard are:

ISOLATORS

Isolators (disconnecting switches) are switches, which operate under no load conditions. They are used in addition to circuit breakers and are provided on each side of circuit breaker to provide isolation and enable maintenance. While opening a circuit, circuit breaker is opened first and then the isolator. While closing a circuit, the isolator is closed first and then the circuit breaker. Isolators are necessary on supply side of circuit breaker to ensure isolation of circuit breaker from live parts for the purpose of maintenance.

EARTHING SWITCH

Earthing switch is connected between line conductor and earth. Normally, it is open. When the line is disconnected, the earthing switch is closed so as to discharge voltage trapped on the line. Generally, earthing switches are mounted on the frame of the isolators.

INSULATORS

Provision of adequate insulation in a sub-station layout is of primary importance from the point of view of reliability of supply and safety of personnel. The following are the considerations to be made: The dielectric strength of the insulating material should be high It should possess high mechanical strength It should posses high resistance to temperature changes The leakage current (to the earth) should be minimum to keep the corona loss and radio interference within reasonable limits The insulator material should not be porous and should be free from impurity and cracks. The following are the insulators normally used: Bus support insulator

Solid core type Poly-cone type Cap and pin type Strain insulators Disc insulators Long rod porcelain insulators Polymer insulators
CARRIER EQUIPMENT

The carrier equipment required for communication, relaying and telemeter is connected to the line through high frequency cable, coupling capacitor and the wave trap. The wave trap is normally installed at the line entrance.
LIGHTNING ARRESTORS

A sub-station has to be shielded against direct lightning strokes by provision of overhead shield wire/earth wire or spikes (masts). Besides direct strokes, the equipments should be protected against travelling waves due to lightning strokes on the lines entering the sub-station. This is done by lightning arrestor. The most important and costly equipment in a sub-station is the transformer and the normal practice is to install lightning arrestors as near to the transformer as possible. Besides protecting the transformer, the lightning arrestor also provides protection to the equipment on the bus side located within certain distances Transformer Transformer is an ac machine that (i) transfer electrical energy from one electric ckt to another (ii) does so without a change of frequency (iii) does so by the principal of electro-magnetic induction and electric ckt that are linked by a common magnetic ckt. Operating principal

The action of transformer is based on the principal that energy may be efficiently transferred by induction from one set of coil to another by means of varying magnetic flux Emf equation Rms value of emf induced = EMF induced per turn* no of turn =4.44*N*f*(flux) Transformer construction The transformer is very simple in construction and consists of magnetic ckt linking with two winding .it consist of a suitable container for assemble core and winding, such as a tank, a suitable medium for insulation from it container such as transformer oil, a suitable bushing for insulating and bringing out terminal of the winding from the container .etc..

Following main part in the transformer construction; 1. Core construction ; A transformer core is the steel system which forms the magnetic with all part pertaining to its construction. and construction Those part of magnetic ckt which carry the transformer winding are called the limbs or legs. The core material should be such that maximum flux is created with minimum magnetizing current and minimum core loss. The magnetic frame of the transformer is built up of laminated electro-technic called transformer grade steel consist of 3.5% silicon. 2. Insulation; steel. Its

Insulation used in transformer may be classified into two major group viz major insulation and minor insulation. Major insulation between winding usually consist of sheet of pressboard and oil ducts. And minor insulation include the insulation provided between the element of a given winding such as conductor insulation, insulation between the turns, layers and coil. 3. Insulation oil; The insulation oil has provides additional insulation , protect the insulation from and moisture and it carries heat away the heat generated in core and coil . 4. Tank; Small capacity tank are fabricated from welded sheet steel, while larger one are assembled from plain boiler plates or cast aluminium parts. 5. Temperature gauge; Every transformer is provided with a temperature gauge to indicate hot oil or hottest spot temperature it is a self contained weatherproof unit made with alarm contact.

7. Oil gange; Every transformer is provided with an oil gange to indicate the oil level 8. Breather;

When the transformer become warm, the oil and gas expand. The gas at the top of the oil is expelled out .when the transformer cools, air is drawn into the transformer. Unless preventive measure are taken, moisture is drawn during the process and it call breathing. 9. Gas operated relay Buchholz relay; It is gas and oil actuated protective device and its practically universally used on all oil immersed transformer having rating more than 750 kva. The use of such relay is possible only transformer having conservator. 10. Bushing; Transformer are connected to hv lines and therefore it care is to be taken to prevent flash-over from the high voltage connection to earthed tank. Connection from cable are made in cable boxes. But overhead connection are to be brought through bushing special designed for different classes of voltage. Type of transformer Depending upon the type of construction: 1. Core type

2. Shell type

Depending upon the type of service, in the field of power system: 1. Power transformer 2. Distribution transformer

1. Power transformer; The term is used to include all transformer of large scale used in generating station and substation for transforming the voltage at each end of a power transmission line.

2. Distribution transformer; The transformer f rating upto 200 kva, used to step down the distribution voltage to a standard service voltage are know as distribution transformer.

Generator
Generator is one of the important type of electric machines. Large ac network operating at constant frequency of 50 hz its called synchronous generator or alternator Operation principal; The operation principal of generator fundamentally same as the dc machine. But in generator there is no need rectify the time varying emf which induced in the armature windingit dont required a commutator. Synchronous generator because of absence of commutator are comparatively simple and possess several important advantage over the dc generator Generator is a synchronous generator which receives mechanical energy from a prime mover to which it is mechanical coupled and drivers electrical energy. Its may be single, two or 3-phase It classified as i)rotating armature type ii)rotating field type

Mechanical systems
Gas Turbine & Auxiliaries The plant has two Gas Turbines of Siemens AG model type V94.2, supplied by BHEL. One Gas Turbine was manufactured at Siemens AG, Germany and the second Gas turbine has been manufactured by BHEL. The Gas Turbine is a single shaft machine of single casing design. Net Output of the Gas Turbine in Open cycle at guaranteed conditions is 143.22 MW. Peak output is 150.51 MW. ISO output of the

machine is 159.8 MW. Compression ratio temperature are 10.5 and 1060 C respectively. Gas Turbine GUARANTED VALUES Type Fuel Lower Calorific Value Net Power Output Nox Emissions Reference Speed Ambient temperature Barometric pressure Relative Humidity Generator power factory Generator Type RPM
0

and

Turbine

Inlet

V 94.2 NATURAL GAS KJ/KG MW PPM (V) Base Load 143.220 50 3000 27 1.013 60 Lagging 0.85 TARI:108/41 Peak load 150.510

bar % --------

Technical Data sheet-Gas Turbine V94.2 1.

Gas Turbine

i. Type / Model ii. Manufacture iii. Firing Fuels

V94.2 BHEL/SIEMENS Natural Gas Main

(Naphtha Alternate HSD Start up/Shut down)

2.

Compressor

Type No. of stage Rated quantity of air flow

Axial flow Heavy duty 16 510 ISO (Kg/sec)

Compressor ratio Type of fixing of rotor discs Rod

11:1 (ISO Firing NG) Hirth serration splined together by Tie Sermetal

Protective coating for compressor blades No. of coated stationary blade rows No. of coated moving blade rows 3. Type No. of combustion Chamber No. of burner / combustion chamber Type of burners Fuel Pressure requirement 80bar (Kg / cm2) Nox level generator 2 8
Combustion System

3+ Inlet Guide Vane

Silo Type

Hybrid Burner NG17.5 to 22 bar, oil approx. at combustion Inlet <50 ppm NG DM

at design condition <65 ppm Oil with water spray Quality of water for Nox suppression 4.
Turbine

Type Axial flow Number of stage 4 Exhaust gas temperature 540 ISO Direction of rotation looking form Compressor side Anti Clockwise Rated speed of the shaft rpm 3000 Trip speed of the shaft rpm 3240 Ignition speed of the shaft 500 Self sustaining speed of the shaft rpm 1200-1400 No. of air cooled stationary rows 3 No. of air cooled moving rows 2 Type of the casing Horizontal Split
NOX Water Injection System

The gas turbines are equipped with water injection arrangement. DM water shall be injected in the combustion chamber to reduce the flame temperature and thereby reduce the NOx emission level during fuel oil operation. There are 2x100% water injection pumps for each of the two gas turbines. The maximum quantity of water injection is 48 ton per hour for one gas turbine at maximum gas turbine out put condition. The system is designed to achieve 65 ppm of NON, during HSD or Naphtha operation. The NOX Water Injection System details are as given below: De- NOX Water Injection Pump Make KSB PUMPS LTD. Capacity 50.4 CuM/hr Head 402 M Motor Make Voltage Rating Current SIEMENS 415 V, 50 Hz, 3 PH 90 KW 150 A

Heat Recovery Steam Generator (HRSG) Two Heat Recovery Steam Generators (HRSG) are installed downstream of two Gas Turbines. HRSGs are unfired water tube, dual pressure, natural circulation type with staggered tube pitch arrangement. These are BHELs Module Steam Generators (MSG) designed for extensivq shop fabrication in order to minimize field installation cost and schedule. The system details of HRSG are as given below: Type OF WHRB Rated Flow T/Hr Rated Press.Ksc Rated Temp.deg Horizontal/ Natural Circulation HP LP 231.131 46.383 81 4.7 530 200

OUT LINE DIMENSIONS Length Height Width 56 M Up to Chimney Center Line 27.4 M Drum Center Line 19.5 M

HP SUPER HEATER AND COMPONENTS

Design Pressure 106 Ksc Design Temperature 569 deg Gas Flow path Area 76.8 Sq. m Depth of each bank Limited to 1800 mm In the direction of gas flow Max. metal temperature 541 deg
HP Main Steam Line

--Pipe Size mm x mm --Material SA 335 P 22

406.4 x 65

LP SUPER HEATER AND COMPONENTS

LP Main Steam Line --Pipe Size mm x mm --Material SA 106 Gr. B 406.4 x12.5

HP EVAPORATOR AND COMPONENTS- CIRCULATION SYSTEM

Total Heating -- Gas Side -- Water/ Steam Side

Surface Area(sqm) 43929 3427

Total No. of Tubes in the bank 1200 -- No. of rows with flow direction 20 -- No. of tubes per row 60 Tube Arrangement Staggered Tube outer diameter mm 51.0

LP EVAPORATOR AND COMPONENTS- CIRCULATION SYSTEM

Total Heating -- Gas Side -- Water/ Steam Side

Surface Area (Sq. m) 31211 2399 840

Total No. of Tubes in the bank

-- No. of rows with flow direction -- No. of tubes per row Tube Arrangement Tube outer diameter mm Tube Thickness mm
HP ECONOMISER AND COMPONENTS

14 60 Staggered 51.0 3.0

Total Heating Sq. m Surface Area -Gas Side 28956 -Water Side 3096 Total No. of tubes in the bank 1520 -- No. of rows with flow direction 19 -- No. of tubes per row 80 Tube Arrangement Staggered Tube Outer diameter mm 38.1 Tube Thickness mm 3.6
LP ECONOMISER AND COMPONENTS

Total Tube Tube Tube

Heating Sq. m Arrangement Staggered Outer diameter mm 51 Thickness mm 3.0

368

CONDENSATE PRE HEATER

Total Heating Sq. m Surface Area --Gas Side 24385 --Water Side 2607 Total No. of tubes in the bank -- No. of rows with flow direction 16 -- No. of tubes per row 80 Tube Arrangement Staggered Tube Outer diameter mm 38.1 Tube Thickness mm 3.0 Steam Turbine & Auxiliaries

1280

There is one steam turbine generator set capable of accepting the entire steam generated by two heat recovery steam generators of the

module. Gross output of Steam Turbine at Generator terminals at design operating conditions is 159.99 MW. The steam turbine is of BHEL make, tandem-compound, condensing, double exhaust having one single flow HP cylinder and one double flow LP cylinder with reaction type bladeing. HPT module is M-30-25 and LPT. module is N30-2x HP turbine has 25 stages and LP turbine has 2X7 stages. The turbine is throttle governed and is capable of accepting variations from the rated conditions within the limits as recommended by IEC-45. The turbine can be operated continuously within the frequency range of 47.5 to 51.5 Hz. The details of Steam Turbine are as given below: SL. 1. 2. 3. 4. 5. 6. 7. 8. 9. STEAM TURBINE Make Rated output Rated steam pressure Rated steam temperature Overall length Overall height Type of blading Type of governing Module No. & details (i) HP (ii) LP Rated Condenser (mm of Hg) M-30-25 (SINGLE FLOW) N-30-2X5 FLOW) Vacuum 0.101 Bar 32 (DOUBLE DESCRIPTION BHEL 156 MW 78 Kg/sq. cm 528 oC 134.4m (approx.) 12.0 m (approx.) REACTION THROTTLE

Rated CW Inlet Temp.0C 10. Type of cylinders HP cylinder

SINGLE FLOW/ HORIZONTAL SPLIT

LP cylinder

DOUBLW FLOW/

HORIZONTAL SPLIT 11.

Operation Range Frequency

Operation Regime a) Continuous Operation b) Limited Operation range continuous at a stretch & total life time c) Speed exclusion range at operation without load d) Standard over speed trip setting

Frequency Range 47.5 Hz to 51.5 Hz Permissible for a maximum 2 hrs during the life of LP Blading speed below 47.5 Hz speed above 51.5 Hz. 11.7 to 47.5/s

55.5/s 12. 13. Turbine (RPM) rated speed 3000

(i) Critical speeds for HP 3812 turbine (RPM) balded rotors (ii) Combined critical speeds 1527, 1814, (RPM) of TG set 5017, 2120. 4187,

14. 15. 18.

Type of turbine gear Turbine speed Turbine Governing system (i) Type (ii) Make

HYDRAULIC 50-60 rpm

ELECTRO HYDRAULIC BHEL THROTTLE

16. 17.

Mode of governing Casing Details HPT Casing a) b) c) d) Type No. of Casings No. of No. of flows Inlet parameters

Split Two

i) Pr. Kg/cm2 ii) Temperature 0C e) Exhaust Parameter i) Pr. Kg/cm2 ii) Temperature C
0

Single -76.4 528.5

51 175 LPT Turbine a) Type b) No. of Casings a) No. of No. of flows b) Inlet parameters Pr. Kg/cm2 ii) Temperature 0C c) Exhaust Parameter Pr. Kg/cm2 Temperature 0C Split Two Single -48.3 200

0.105 46.1

Shaft Seal Assembly and Seal Steam System The external shaft seals at the rotor ends of steam turbine prevent the ingress of air through any of the shaft seals and discharge of steam to atmosphere. They perform these functions in conjunction with the shaft seal steam supply system. HP rear end and LP front and rear shaft seals are See through type. The advantage of this type of seal is that it is possible to optimize spacings between the seal strips regardless of relative expansions between rotor and

housing. HP front end has labyrinth type seals. Seal steam from LP steam lines of the HRSGs, is fed to seals through a self contained hydraulic actuated pressure control valve during startup and low load operation. At higher load leak-off from HP turbine glands supplies sealing steam through a pressure control valve similar to seal steam control valve. 2x100% seal steam exhauster fans extract steam-air mixture from turbine glands to maintain slight vacuum avoiding steam leakage to atmosphere. Gland Steam Exhauster i) Number of pumps in service (No.) ii) Make & type iii)Size iv)Speed (RPM) v) Motor rating (kw) ONE (1) + One (1) Stand By SK Systems Pvt Ltd. 12.5 x C1 2840 2.2

Condenser The condenser is box type construction with divided water box, two pass, spring supported, and welded with exhaust-hood of the LP turbine. The condenser is designed for a heat load of 274.1135 X 106 Kcal/hr, and design circulating water quantity is 26800 m3 per hour. Temperature rise of cooling water at design point is 10.220 C. The condenser is provided with integral aircooling section where air and non-condensable gases are drawn out with help air evacuation equipment. The condenser is fitted with welded Stainless steel tubes (grade SS TP 304). Water boxes are dome shaped removable type and are provided with necessary hinged manholes for easy access to the interior for inspection. 2x100% vacuum pumps are provided for maintaining the vacuum in condenser. The vacuum pumps are of liquid ring type with rotor eccentric to the casing. Pumps are designed for hogging as well as holding operation. During hogging operation, both pumps will work simultaneously for quick evacuation, while during holding operation one pump will operate.

Main Steam System The steam generated by individual HRSG is discharged into separate HP and LP headers. Both HP and LP steam lines are provided with following features: i) Motorised steam isolation valves in individual steam lines from each HRSG near the common steam header going to the steam turbine. ii) Motorised steam stop valves near each FIRSG to facilitate the maintenance of individual HRSG and carryout the hydraulic test etc. iii) Individual bypass lines from individual HPILP steam lines from HRSG upstream of motorised steam isolation valve. iv) Suitable warm up arrangement for HP steam lines. The steam for deaerator pegging is tapped off from the individual steam lines with two motorised isolation valves. These are joined together and a common line is run up to the deaerator. Sealing steam for steam turbine is also taken from this header.

STEAM PRESSURES

Rated

Longtime

Short time

Operation Operation Initial steam Ahead of Ist HP drum stage At Ist cylinder exhaust 76.04 74.9 5.1 87.9 86.1 5.9 6.4 5.6 0.3 99.4 86.1 5.9 12 5.6 0.3 Bar Bar Bar Bar Bar Bar

At inlet to induction stem 5.6 valve At inlet to second cylinder At second cylinder exhaust 4.83 0.101 5

Short time operation: Permissible momentary value. The aggregate duration of such swings must not exceed 12 hours in any one year

STEAM TEMPERATURES

Read value Annual mean value

Long-time 400 h 40 h per annum max. value but per 15 min in individual keeping annum case within annual mean value 531.6 208.0 542.2 214.0 556.1 228.0
0

Initial steam

528.2

C C

At inlet to 200.0 LP steam valve At 1st 175.0 cylinder exhaust At 2nd 181.8 cylinder inlet At 2nd 46.1 cylinder exhaust Condensate System

200.9

212.9

340

0C

207.7

221.7

228.0

0C

70

70

, 2100% () . 700 3/ 225 . (). . , . ,

 . . () . 350% , . . . . , . , 2100% , .

Feed Water System

Water from deaerator feed storage tank is fed to HP Economiser and LP Economiser circuits of the two HRSGs by means of HP and LP feed water pumps (each 3x50%). Six separate outlet connections are provided from the deaerator for suction of the pumps. Design rating of each HP Feed Pump is 325 m3/hour and 1500 MLC. HP Feed water pumps are high pressure, multistage, horizontal, barrel casing, removable cartridge type rotating elements, centrifugal pumps. Single stage Booster pump ensures that NPSH requirements of HP Feed pumps are met in all operating conditions. A common motor drives both booster pump and Feed pump through a constant speed mechanical gearbox. Design rating of each LP Feed Pump is 67 m3/hour and 172 MLC. LP BFPs are also horizontal multistage type centrifugal pumps, with Ring section design. Both HP and LP Feed Pumps are provided with minimum re-circulation lines from the discharge of each pump, for maintaining the minimum flow requirement of each pump. The minimum recirculation lines are connected back to feed storage tank.
HP BOILER FEED PUMP

GENERAL Designation No. of Pumps Type of Operation Type of pumps` Type of Drive DESIGN PARAMETERS Liquid handled Temp of feed water, 0C Specific weight of feed Water kg/m3 Suction flow, m3 /hr Dynamic Head, mlc Speed, rpm Power input to pump, KW Efficiency of pump,%

HP Boiler Feed Pump 3x 50% Continuous FK 6D 30 Motor Feed water 155.7 911.2 325 1404 4200 1400 81

LP BOILER FEED PUMP Make Type Capacity Head MOTOR Make Kirloskar Electric Co. Kirloskar EBARA Pumps Ltd 100 x 80 MSS4M 66.4 CuM/ Hr 180 M

Control and instrumentation

In the FGPS, application of instrumentation and control systems are for centralized, automated and safe plant control of equipments like gas turbines, heat recovery steam generators (HRSG), steam turbine generator and their auxiliaries to achieve maximum efficiency, reliability, safety and availability. There is optimum plant control due to these controlled instrumentation and control system. In the plant, C&I systems are microprocessor based with functionally distributed panels i.e. for different signals there are different microprocessors based input output cards. Instrumentation and control panels are provided for each gas turbine generator and steam generator.

THE

MAJOR COMPONENTS FOLLOWING

IN

THE

SYSTEM

INCLUDE

THE

The The The The

analog control system binary logic control system data acquisition and processing system power supply system

The operation of the power plant is controlled from the central control room in which the control panels are located. Provision is made for local starting and testing of the important equipments, pumps and motors.

The control panels accommodate keyboards for CRTs, Auto-Manuals stations, set-point stations, sequential control modules, push button modules, selector switches, emergency shutdown devices, etc.

Protection

Chemical analysis/water treatment analysis

A large quantity of water is used in boiler for generation the steam. The water used in boiler is called boiler feed water. Hard water creates a number of problems like corrosion, scale and sludge formation etc. Natural water is not directly used in boiler because it contains hardness producing salts. Hence water should be properly softened and pure before feeding into boiler. To softened and pure water following methods: *By removal of dissolved oxygen& CO2

---- by mechanical deaeration method *By adding of alkali Mechanical deaeration method used in NTPC for purification water