BRIEF PROFILE OF THE COMPANY

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 are generation of electricity and its total installed capacity is 747.0 M.W. including of Pragati Power Station, its associate Company is which was incorporated on 9th January, 2001. GAS TURBINE The burning of fossil fuels (coal, natural gas, or petroleum). In hot gas (gas turbine), turbines are driven directly by gases produced by the combustion of natural gas or oil. Combined cycle gas turbine plants are driven by both steam and natural gas. They generate power by burning natural gas in a gas turbine and use residual heat to generate additional electricity from steam. These plants offer efficiencies of up to 60%.

COMBINED CYCLE In electric power generation a combined cycle is an assembly of heat engines that work in tandem off the same source of heat, converting it into mechanical energy, which in turn usually drives electrical generators. The principle is that the exhaust of one heat engine is used as the heat source for another, thus extracting more useful energy from the heat, increasing the system's overall efficiency. This works because heat engines are only able to use a portion of the energy their fuel generates (usually less than 50%). The remaining heat (e.g., hot exhaust fumes) from combustion is generally wasted. Combining two or more thermodynamic cycles results in improved overall efficiency, reducing fuel costs. In stationary power plants, a successful, common combination is the Brayton cycle (in the form of a turbine burning natural gas or synthesis gas from coal) and the Rankine cycle (in the form of a steam power plant). Multiple stage turbine or steam cylinders are also common. In automotive and aeronautical engines, turbines have been driven from the exhausts of Otto, Diesel, and Crower cycles. These are called turbo-compound engines. Aside from turbochargers, they have failed commercially because their mechanical complexity and weight are less economical than multistage turbines. Stirling engines are also a good theoretical fit for this application. In a combined cycle power plant (CCPP), or combined cycle gas turbine (CCGT) plant, a gas turbine generator generates electricity and heat in the exhaust is used to make steam, which in turn drives a steam turbine to generate additional electricity. This last step enhances the efficiency of electricity generation. Design principle

Working principle of a combined cycle power plant

In a thermal power station water is the working medium. High pressure steam requires strong, bulky components. High temperatures require expensive alloys made from nickel or cobalt, rather than inexpensive steel. These alloys limit practical steam temperatures to 655 C while the lower temperature of a steam plant is fixed by the boiling point of water. With these limits, a steam plant has a fixed upper efficiency of 35 to 42%. An open circuit gas turbine cycle has a compressor, a combustor and a turbine. For gas turbines the amount of metal that must withstand the high temperatures and pressures is small, and lower quantities of expensive materials can be used. In this type of cycle, the input temperature to the turbine (the firing temperature), is relatively high (900 to 1,400 C). The output temperature of the flue gas is also high (450 to 650 C). This is therefore high enough to provide heat for a second cycle which uses steam as the working fluid; (a Rankine cycle). In a combined cycle power plant, the heat of the gas turbine's exhaust is used to generate steam by passing it through a heat recovery steam generator (HRSG) with a live steam temperature between 420 and 580 C. The condenser of the Rankine cycle is usually cooled by water from a lake, river, sea or cooling towers. This temperature can be as low as 15 C In an automotive power plant, an Otto, Diesel, Atkinson or similar engine would provide one part of the cycle and the waste heat would power a Rankine cycle steam or Stirling engine, which could either power ancillaries (such as the alternator) or be connected to the crankshaft by a turbo compoundingsystem
Typical size of CCGT plants

For large scale power generation, a typical set would be a 270 MW gas turbine coupled to a 130 MW steam turbine giving 400 MW. A typical power station might comprise of between 1 and 6 such sets. Plant size is important in the cost of the plant. The larger plant sizes benefit from economies of scale (lower initial cost per kilowatt) and improved efficiency. A single shaft combined cycle plant comprises a gas turbine and a steam turbine driving a common generator. In a multi shaft combined cycle plant, each gas turbine and each steam turbine has its own generator. The single shaft design provides slightly less initial cost and slightly better efficiency than if

the gas and steam turbines had their own generators. The multi shaft design enables 2 or more gas turbines in conjunction with a single steam turbine, which can be more economical than a number of single shaft units. The primary disadvantage of multiple stage combined cycle power plant is that the number of steam turbines, condensers and condensate systems-and perhaps the cooling towers and circulating water systems increases to match the number of gas turbines. For multiple shaft combined cycle power plant there is only one steam turbine, condenser and rest of the heat sink for up to three gas turbines, only their size increases. Having only one large steam turbine and heat sink results in low cost because of economics of scale. Further a large steam turbine also allows the use of high pressure and efficient steam cycle. Thus the overall plant size and the associated number of gas turbines required have a major impact on whether single shaft combined cycle power plant or multiple shaft combined cycle power plant is more economical.

Efficiency of CCGT plants

(When talking about the efficiency of heat engines and power stations the convention should be stated ie HHV (aka Gross Heating Value etc) or LCV (aka Net Heating value) AND whether Gross output (at the generator terminals) or Net Output (at the power station fence) are being considered. The two are of course separate but both must be stated. Failure to do so causes endless confusion.) In general in service Combined Cycle efficiencies are over 50 percent on an on a lower heating value and Gross Output basis. Most combined cycle units, especially the larger units, have peak, steady state efficiency efficiencies of 55 - 59%. By combining both gas and steam cycles, high input temperatures and low output temperatures can be achieved. The efficiency of the cycles add, because they are powered by the same fuel source. So, a combined cycle plant has a thermodynamic cycle that operates between the gas-turbine's high firing temperature and the waste heat temperature from the condensers of the steam cycle. This large range means that the Carnot efficiency of the cycle is high. The actual efficiency, while lower than this, is still higher than that of either plant on its own. The actual efficiency achievable is a complex area. The electric efficiency of a combined cycle power station, calculated as electric energy produced as a percent of the lower heating value of the fuel consumed, may be as high as 58 percent when operating new, ie unaged, and at continuous output which are ideal conditions. As with single cycle thermal units, combined cycle units may also deliver low temperature heat energy for industrial processes, district heating and other uses. This is called cogeneration and such power plants are often referred to as a Combined Heat and Power (CHP) plant.
Boosting Efficiency

The efficiency of CCGT and GT can be boosted by pre-cooling combustion air. This is practiced in hot climates and also has the effect of increasing power output. This is achieved by evaporative cooling of water using a moist matrix placed in front of the turbine, or by using Ice storage air conditioning. The latter has the advantage of greater improvements due to the lower temperatures available. Furthermore, ice storage can be used as a means of load control or load shifting since ice can be made during periods of low power demand and, potentially in the future the anticipated high availability of other resources such as renewables during certain periods.
Supplementary firing and blade cooling

Supplementary firing may be used in combined cycles (in the HRSG) raising exhaust temperatures from 600C (GT exhaust) to 800 or even 1000C. Using supplemental firing will however not raise the combined cycle efficiency for most combined cycles. Only for one pressure boilers it may raise the efficiency if fired up to approximately 700- 750C. For multiple pressure boiler however supplemental firing is often used to improved peak power production of the unit, or to enable large steam production to compensate failing of e.g. a second unit. Maximum supplementary firing refers to the maximum fuel that can be fired with the oxygen available in the gas turbine exhaust. The steam cycle is conventional with reheat and regeneration. Hot gas turbine exhaust is used as the combustion air. Regenerative air preheater is not required. A fresh air fan which makes it possible to operate the steam plant even when the gas turbine is not in operation,increases the availability of the unit. The HRSG can be designed with supplementary firing of fuel after the gas turbine in order to increase the quantity or temperature of the steam generated. Without supplementary firing, the efficiency of the combined cycle power plant is higher, but supplementary firing lets the plant respond to fluctuations of electrical load. Supplementary burners are also called duct burners.
Configuration of CCGT plants

The combined-cycle system includes single-shaft and multi-shaft configurations. The single-shaft system consists of one gas turbine, one steam turbine, one generator and one Heat Recovery Steam Generator (HRSG), with the gas turbine and steam turbine coupled to the single generator in a tandem arrangement on a single shaft. Key advantages of the single-shaft arrangement are operating simplicity, smaller footprint, and lower startup cost. Single-shaft arrangements, however, will tend to have less flexibility and equivalent reliability than multi-shaft blocks. Additional operational flexibility is provided with a steam turbine which can be disconnected, using an synchro-self-shifting (SSS) Clutch,[5] for start up or for simple cycle operation of the gas turbine. Multi-shaft systems have one or more gas turbine-generators and HRSGs that supply steam through a common header to a separate single steam turbine-generator. In terms of overall investment a multi-shaft system is about 5% higher in costs. OPEN CYCLE

In open cycle operation of a gas turbine power plant the flue gases generated are not utilized for the formation of steam( to drive stream turbine unit in power plant ) as in combined cycle , instead it is sent to treatment unit and then to exhaust chimneys. This results in an overall less efficiency as a useful part of energy (heat) is wasted. The initial cost for the open cycle plant is lesser than combined cycle plant.

PLANT OVERVIEW AND OPERATION

Plant overview shows the temperature and pressure at each unit of power plant. It is observed in the control room. In the image we can see two separate gas turbine units and two HRSGs above which there are LP and HP drums which drive the HPT and LPT which are mounted on the same shaft connected to STG. Air is taken from atmosphere and passed through air filters and cleaned and then sent to compressor units. Air is compressed and then mixed with natural gas in the combustion chamber. Flue gases are

generated at high pressure and temperature when the mixture of air and natural gas is ignited by spark plugs along the walls of combustion chamber. These flue gases drive the gas turbine , inlet temperature of flue gas is about 1170 degree Celsius and around 570 at outlet. Now the flues gases are sent into HRSG unit where along with steam generation(evaporator ) the flue gases are passed through superheaters and economizers generating high pressure and low pressure steam which is then stored in HP and LP drums. One HRSG unit consists of two chimneys/stacks on bypass stack and other main stack. Bypass stack is used to exhaust gases when there is need for maintenance in the in HRSG unit. It is in the beginning of HRSG and main stack is at the end. The flue gases are passed into the atmosphere at the temperature of 110 degree centigrade. Evaporator Section: The most important component would, of course, be the Evaporator Section. So an evaporator section may consist of one or more coils. In these coils, the effluent (water), passing through the tubes is heated to the saturation point for the pressure it is flowing. Superheater Stionec: 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. Economizer Section: The Economizer Section, sometimes called a preheater or preheat coil, is used to preheat the feedwater being introduced to the system to replace the steam (vapour) being removed from the system via the superheater or steam outlet and the water loss through blowdown. It is normally located in the colder gas downstream of the evaporator. Since the evaporator inlet and outlet temperatures are both close to the saturation temperature for the system pressure, the amount of heat that may be removed from the flue gas is limited due to the approach to the evaporator, whereas the economizer inlet temperature is low, allowing the flue gas temperature to be taken lower

The steam generated in two HP drums and two LP drums is used to drive the HP turbine and LP turbine(8 stage four on each side). The steam outlet from HP turbine is sent to deaerator from where it is sent to LP drum and also into HRSG unit with the help of LPBFP and HPBFP. The steam from HP drum is recycled whereas steam from LP drum after driving the turbine is collected into condenser where it is cooled and sent to GSC using CEP(condensate extraction pump) this water is again used for the generation of steam.

ELECTRICAL UNIT

Basic SLD of power plant

it shows two gas turbine generators and one steam turbine generator along with their main transformers and unit auxiliary transformers also there circuit breakers and exciters. The winding temperature of each transformer is also shown. Again it is observed and controlled by control room.

STG UNIT :

It consist of a main transformer with Yn d11 type connection, i.e. HT side is star connected with neutral grounded and LT side delta connected. The main transformer has three different modes of cooling.
a) b) ONAN : oil natural air natural ,73 MVA rated capacity in this mode ONAF : oil natural air forced , 102.2 MVA rated capacity in this mode OFAF : oil forced air forced , 146 MVA rated capacity in this mode

c)

these modes are described on the basis of temperature rise in winding at different loads. Class of insulation is A for the windings. Transformer is fed by Isolated phase busduct rated 8900amps and connected in series is CB also rated 8900amps after which a steam turbine generator is connected via the busduct whose neutral is grounded by NGT which is magnetically linked with NGR (neutral ground relay which operates in case of an earth fault in STG ). Rated generation capacity of STG is 122 MW

Two GTG units :

Two GTG units are there in the plant each rated for 104 MW , above is SLD for one GTG unit It consists of a main transformer similar connection but maximum rating of 114MVA. Unit also consists of isolated phase busduct and CB rated at 7000amps. There is unit auxiliary transformer which feeds the loads in GTG , UAT is step down transformer it provides a rated voltage of 6.6 KV to drive the starting motor and other loads, forced oil cooling is not required in UAT. UAT draws power from transmission lines when it is required to restart the GTG unit. Same as STG unit the generator in these units are grounded via NGT. The two GTG units are similar and entirely separate from each other each capable of generating a maximum 104MW .Have separate UATs and starting motor for each unit . If due to some fault system goes out of service and to restart the units again for generation of power and to take care of comparatively smaller loads in the plants UAT draws power from the t/m lines connected to grid , while in case of an entire blackout a DGSET is installed the power plant to restart the system. DGSET : Diesel Generator SET operated in case of blackout, it can be used to restart the system or for the safe shut down of the generator unit. The turbine of generators is operated by driving medium which is at high temperature so if we stop the generator instantly the turbine and shaft at high temperature will bend due to localized cooling. To avoid this phenomenon the shaft must be kept in rotation for uniform

cooling. Usually the turbine is rotated for around two days continuously for safe shut down of generator unit. Two UATs feeds ten small transformers which then keeps the plant operational and running. The nameplate rating of one such transformer :

These transformers feed the small loads like lighting, ventilation , lifts , plugpoints and some small motors which are helpful in smooth operation of power plant. There are net 5 different types of transformer each unit of 5 transformers is fed by both UATs and all the ten transformers can be fed from one UAT in case one of the unit is closed.

PROTECTION Power systems contain protective devices to prevent injury or damage during failures. The quintessential protective device is the fuse. When the current through a fuse exceeds a certain threshold, the fuse element melts, producing an arc across the resulting gap that is then extinguished, interrupting the circuit. Given that fuses can be built as the weak point of a system, fuses are ideal for protecting circuitry from damage. circuit breakers - devices that can be reset after they have broken current flow. In modern systems that use less than about 10 kW, miniature circuit breakers are typically used. These devices combine the mechanism that initiates the trip (by sensing excess current) as well as the mechanism that breaks the current flow in a single unit. Some miniature circuit breakers operate solely on the basis of electromagnetism. In these miniature circuit breakers, the current is run through a solenoid, and, in the event of excess current flow, the magnetic pull of the solenoid is sufficient to force open the circuit breaker's contacts (often indirectly through a tripping mechanism). A better design however arises by inserting a bimetallic strip before the solenoid - this means that instead of always producing a magnetic force, the solenoid only produces a magnetic force when the current is strong enough to deform the bimetallic strip and complete the solenoid's circuit. In higher powered applications, the protective relays that detect a fault and initiate a trip are separate from the circuit breaker. Early relays worked based upon electromagnetic principles similar to those mentioned in the previous paragraph, modern relays are application-specific computers that determine whether to trip based upon readings from the power system. Different relays will initiate trips depending upon different protection schemes. For example, an overcurrent relay might initiate a

trip if the current on any phase exceeds a certain threshold where as a set of differential relays might initiate a trip if the sum of currents between them indicates there may be current leaking to earth. The circuit breakers in higher powered applications are different too. Air is typically no longer sufficient to quell the arc that forms when the contacts are forced open so a variety of techniques are used. The most popular technique at the moment is to keep the chamber enclosing the contacts flooded withsulfur hexafluoride (SF6) - a non-toxic gas that has superb arc-quelling properties.

TYPES OF PROTECTION Generator sets In a power plant, the protective relays are intended to prevent damage

to alternators or of the transformers in case of abnormal conditions of operation, due to internal failures, as well as insulating failures or regulation malfunctions. Such failures are unusual, so the protective relays have to operate very rarely. If a protective relay fails to detect a fault, the damage to the alternator or to the transformer may have important financial consequences for the repair or replacement of equipment and the value of the energy that otherwise would have been sold. High voltage transmission network Protection on the transmission and distribution serves

two functions: Protection of plant and protection of the public (including employees). At a basic level protection looks to disconnect equipment which experience an overload or a connection to earth. Some items in substations such as transformers may require additional protection based on temperature or gassing among others. Overload Overload protection requires a current transformer which simply measures the

current in a circuit. If this current exceeds a pre-determined level, a circuit breaker or fuse should operate. Earth fault Earth fault protection again requires current transformers and senses an

imbalance in a three-phase circuit. Normally a three-phase circuit is in balance, so if a single (or multiple) phases are connected to earth an imbalance in current is detected. If this imbalance exceeds a pre-determined value a circuit breaker should operate. Distance Distance protection detects both voltage and current. A fault on a circuit will

generally create a sag in the voltage level. If this voltage falls below a pre-determined level and the current is above a certain level the circuit breaker should operate. This is useful on long lines where if a fault was experienced at the end of the line the impedance of the line itself may inhibit the rise in current. Since a voltage sag is required to trigger the protection the current level can actually be set below the normal load on the line.

Back-up At all times the objective of protection is to remove only the affected portion of

plant and nothing else. Sometimes this does not occur for various reasons which can include: Mechanical failure of a circuit breaker to operate Incorrect protection setting Relay failures

A failure of primary protection will usually result in the operation of back-up protection which will generally remove both the affected and unaffected items of plant to remove the fault. Low-voltage networks The low voltage network generally relies upon fuses or low-

voltage circuit breakers to remove both overload and earth faults.