Mahatma Gandhi Missions

College of Engineering and Technology.

Noida, U.P., India
Report on Practical Industrial Training
Carried out at
Pragati power station , New Delhi
From 16-06-1 to 11-0!-1"
#cedemic $ear %01&-%01
Submitted by: Submitted to:
Name: ADARSH BHADAURIA
Class:BT ME Mechanical Engineeing De!atment"
Uni#$ Roll No:%%&'()&&&) M*M+s C,ET"
Noida
1
Mahatma Gandhi Missions
College of Engineering and Technology.
Noida, U.P., India
Department o' (echanical )ngineering
C)RTIFIC#T)
This is to certify that Mr. / Ms. ADARSH BHADAURIA of B. Tech. Mechanical
Engineering, Class BT ME Roll No 03. has completed / partially completed / not
completed his / her Industrial Training during the academic year 20!"20# from
16-06"1 to 11"06"1 at !RA"ATI !#$ER STATI#%-1&%E$ DE'HI.
Training Coordinator *ead o' the Department
2
AC-N,./ED*EMENT
I am a )th yea student 0om M*M+s college o0 engineeing and technology" Noida 1U$23 $I 4as a!!ointed to do
) 4ee5s taining at this esteemed ogani6ation 0om %7
st
8une 9&%) to %%
th
8uly 9&%)$
I 4as assigned to #isit #aious di#ision o0 the !lant" 4hich 4ee:
.ate teatment !lant
*as tubine section
Steam tubine section
This taining 4as a #ey educational 0o me$ It 4as eally ama6ing to see the !lant by mysel0 and lean ho4
electicity is !oduced$ This e!ot has been made by my e:!eience at 22S;%$ The mateial in this e!ot has
been gatheed 0om my te:tboo5 and taines manuals !o#ided by taining de!atment$ The s!eci0ication and
!inci!les ae as leaned by me 0om the em!loyees o0 each di#ision o0 22S;%$
3
ABSTRACT
This e!ot contains the 4o5ing o0 !agati !o4e station " Ne4 Delhi$ !agati !o4e station is a combined gas
cycle !o4e !lant$ It contains t4o ty!es o0 !o4e !oducing tubines namely steam tubines and gas tubines$
These ae #ey 4ell connected and use out!ut o0 each othe at #ey geat e:tent$ The !lant also contains 4ate
teatment !lant$ The gas 4hich is su!!lied to the gas tubine is su!!lied by *AI/ 1gas authoity o0 India
limited3$ This e!ot also contains all the s!eci0ications o0 !o4e !lant$
4
T#+,) -F C-NT)NT.
C-NT)NT. Page no"
C*#PT)R-1 About the com!any <
C*#PT)R-% *as Tubine section %&
9$% .o5ing o0 gas tubine %%
9$%$% 2inci!le o0 o!eation %9
9$9 Main Com!onents o0 gas tubine %=
9$= Ai inta5e system %)
9$=$% Com!esso %(
9$=$9 Combusto %(
9$) Tubine section %>
9$( *as tubine accessoy systems %>
9$7 E:haust system %>
9$< Au:iliay com!onents o0 gas tubine %>
9$<$% *as tubine state %'
9$> Inlet ai 0iltes 9%
9$>$% Ai 0ilte house 9%
9$' ?an ai cooles 99
C*#PT)R-& Steam tubine section 9=
=$% .o5ing cycle 9(
=$9 2ocesses in Ran5ine cycle 9(
=$= Constuctional 0eatues 97
=$=$% H$2$ Tubine 97
=$=$9 /$2$ Tubine 97
=$=$= blading 9<
5
=$=$) Beaings 9<
=$=$( Sha0ts glands and Inte stage sealing 9>
=$=$7 @al#es 9'
=$) Tubine go#ening system 9'
=$( Tubine motoing system 9'
=$7 Technical s!eci0ications =&
R)F)R)NC). =%



6
,I.T -F FI/0R).
,I.T Page no$
?ig$ %$% 2agati !o4e station >
?ig$ 9$% *as tubine %&
?ig$ 9$9 .o5ing o0 Bayton cycle %%
?ig$ 9$= Com!onents o0 gas tubine %=
?ig$ 9$) Ai inta5e system %)
?ig 9$( Com!esso House %7
?ig$ 9$7 *as tubine mounted 4ith multi can combustos %<
?ig 9$< Au:iliay systems o0 gas tubine 9&
?ig$ 9$> Ai ?ilte house 9%
?ig$ 9$' Ai 0iltes 9%
?ig$ 9$%& ?an ai cooles 99
?ig$ =$% Steam tubine 9=
?ig$ =$9 Steam tubine blading 9)
?ig$ =$= !ocesses in an5ine cycle 9(
?ig$ =$) Blading 9<
?ig" =$( sha0t gland and inte stage sealing 9>
?ig$ =$7 #al#es 9'
?ig$ =$< Tubine motoing system =&
7
CHA2TER %
AB,UT THE C,M2ANA
8
?ig$ %$% 2agati !o4e station
2agati 2o4e Co!oation /imited is an undeta5ing o0 *o#enment o0 NCT o0 Delhi$ It 4as inco!oated on
'th 8anuay"9&&% to undeta5e !o4e geneation acti#ities 0o su!!lying !o4e to Delhi$ It is one o0 the leading
Undeta5ings o0 *NCTD" geneating !o0its since ince!tion and !aying di#idends egulaly$It is !esently
9
ha#ing ca!ital base o0 9"&%' coes and asset base o0 ="=%' coes$ The !oBected asset base and e#enue
income o0 Com!any in the nea 0utue ae 7"&&& coes and ("&&& coes es!ecti#ely$ The 0ist !oBect
undeta5en by the com!any 4as ==& M. gas based CC*T 4hich 4as 0ully commissioned in the yea 9&&=;&)$
The station is !esently o!eating at abo#e >(C a#ailability$22C/ is !esently setting u! a %(&& M. *as Based
CC*T !lant at Ba4ana in Noth;.est Delhi to augment the !o4e geneation at /oad; Cente$ 2oBect is
e:!ected to 0ully commission by 8uly 9&%%$ 22C/ is also !o!osing to !ut u! a <(& M. *as Based CC*T at
Bamnauli in South;.est Delhi$ The !oBect is e:!ected to be commissioned in the yea 9&%=;%)$
To ha#e eliable su!!ly to the Ca!ital City" a ==& M. combined cycle *as Tubine 2o4e 2oBect 4as set u! by
22C/ on 0ast tac5 basis$ The !lant consists o0 9 : %&) M. *E ?ame ';E *as Tubine Units commissioned in
9&&9 D &= and % : %99 M. ST* Unit commissioned in 9&&= D &)$ The station is using A2M" 2MT and R;/N*
*as" su!!lied by *AI/ though HB8 2i!eline$ The station is !e0oming 4ell and has achie#ed a#ailability o0
moe than>(C$ The !o4e geneation 0om the station is !um!ed to the adBacent 99&5@ Sub Station o0 Delhi
Tansco /imited and the entie !o4e is su!!lied to the discoms o0 Delhi i$e$ ND2/" NDMC" BR2/ E BA2/$
The S!ecial 0eatues o0 the !lant ae as unde:
Due to !aucity o0 4ate in the ca!ital city" the !lant is o!eating on teated se4age 4ate su!!lied 0om
Sen Nusing Home E Delhi *ate ST2s$ The ST2 4ate is 0uthe teated in R,;DM 2lant$
Emission o0 o:ides o0 Nitogen 1No:3 has been limited to =( 22M" lo4est in the county" 0o 4hich
s!ecial technology is used by installing Dy /o4 No: 1D/N3 Combustos$ This is the 0ist !lant in India
4ith a 0acility to contol No:$ Emission$
The !lant e00luent is dischaged to i#e Aamuna a0te neutali6ing and thus the e00luent dischage is
bette than i#e 4ate" ma5ing the !oBect eco;0iendly$
CHA2TER 9
10
*AS TURBINE SECTI,N
?ig 9$% *as tubine
A gas tubine is a otay machine" 4hich consists o0 thee main com!onents ; a com!esso" a combustion
chambe" and a tubine$ The ai a0te being com!essed into the com!esso is heated eithe by diectly buns
0uel in it o by buning 0uel e:tenally in a heat e:change$ The heated ai 4ith o 4ithout !oducts o0
combustion is e:!anded in a tubine esulting in 4o5 out!ut" a substantial !at" about t4o;thids" o0 4hich is
used to di#e the com!esso$ The est" about one;thid" is a#ailable as use0ul 4o5 out!ut$ A gas tubine e:tacts
enegy 0om a 0lo4 o0 hot gas !oduced by combustion o0 gas o 0uel oil in a steam o0 com!essed ai$ It has an
u!steam ai com!esso 1adial o a:ial 0lo43 mechanically cou!led to a do4nsteam tubine and a combustion
chambe in bet4een$ F*as tubineF may also e0e to Bust the tubine element$
Enegy is eleased 4hen com!essed ai is mi:ed 4ith 0uel and ignited in the combusto$ The esulting gases ae
diected o#e the tubineGs blades" s!inning the tubine" and mechanically !o4eing the com!esso$ Enegy is
e:tacted in the 0om o0 sha0t !o4e" com!essed ai and thust" in any combination" and used to !o4e aica0t"
tains" shi!s" electical geneatos" and e#en tan5s$ The gas tubine at 2$2$C$/ is o0 B$H$E$/ model MS '&&&" is a
11
sim!le cycle" single sha0t gas tubine 4ith a %) combustion chambes" e#ese 0lo4 combustion system$ The
tubine assembly is consist o0 0ollo4ing si: maBo sections o gou!s
%"1 1-R2IN/ C3C,) -F /#. T0R+IN)
Bayton cycle is the 4o5ing cycle o0 gas tubine$
?ig$ 9$9 .o5ing o0 Bayton cycle
%;9 isento!ic com!ession 1in com!esso3

9;= const$ !essue heat;addition 1in combustion chambe3

=;) isento!ic e:!ansion 1in tubine3
12

);% const$ !essue heat eBection 1e:haust 3
%"1"1 Principle o' operation
Inta5e
;Slo4 do4n incoming ai
;Remo#e distotions
Com!esso
; Dynamically com!ess ai
Combusto
;Heat addition though chemical eaction
Tubine
;Run the com!esso
No66leH ?ee Tubine
;*eneation o0 thust !o4eHsha0t !o4e
/as tur4ine essentiall$ consists o' 'ollowing sections:
2imay Section consists o0:;
Ai Inta5e system ha#ing <>) !ais o0 cylindical and conical catidge 0iltes
Com!esso Section ha#ing %> stages o0 the oto and state Blading:
Combusto 1Combustion Chambe3 consists o0 %> combustos coss 0ie tubes" 0uel no66les" s!a5 !lug
ignites and 0lame detectos$
Tubine Section ha#ing = stages
13
E:haust system
%"% (#IN C-(P-N)NT. -F /#. T0R+IN)
?ig$ 9$= com!onents o0 gas tubine
%"& #IR INT#2) .3.T)(
14
?ig 9$) Ai inta5e system
9$=$% C,M2RESS,R
Compressor used in gas tur4ine is #5ial 6Flow t$pe
15
High 2e0omance Made 2ossible by Ad#anced Aeodynamics" Coatings" and Small Blade Ti! Cleaances
E#en Small Amounts o0 De!osits on Com!esso Blades May Cause /age 2e0omance /ossesAs ai 0lo4s
into the com!esso" enegy is tans0eed 0om its otating blades to the ai$ 2essue and tem!eatue o0 the ai
incease$ Most com!essos o!eate in the ange o0 <(C to >(C e00iciency$
9$=$9 C,MBUST,R
The !u!ose o0 the combusto is to incease the enegy stoed in the com!esso e:haust by aising its
tem!eatue$ Combustion ai" 4ith the hel! o0 s4ile #anes" 0lo4s in aound the 0uel and mi:es 4ith the 0uel$
This ai is called !imay ai and e!esents a!!o:imately 9( o0 total ai ingested by the engine$ The 0uel;ai
mi:tue by 4eight is oughly %( !ats o0 to % !at o0 0uel$ The emaining <( !ecent o0 the ai is used to 0om an
ai blan5et aound the buning gases and to lo4e the tem!eatue$
C-(PR)..-R .)CTI-N
16
?ig$ 9$( Com!esso house
17
C,MBUST,R
?ig 9$7 *as tubine mounted 4ith multi can combustos
%" Tur4ine .ection
18
The thee;stage tubine section is the aea in 4hich the enegy in the hot !essui6ed gas !oduced by
com!esso and combustion sections is con#eted into mechanical enegy$
The 0ist stage o0 tubine oto blade consists o0 blades$
Ai cooling aangements ae !o#ided 0o tubine %
st
and 9
nd
stage$

%"7 /as Tur4ine #ccessor$ .$stems
Stating System To get com!esso initially otated" stating moto !o#ide 7 !m Then e:citation to can5 till
<&& !m ,nce at )&&;)9& !m" 0uel inBected and s!a5 ignited % min$ 4am u! time Acceleating mode aound
=&&& !m at ?SN/ 2o4e Tansmission System Reduction geas used to tans0e toIue .ith s!lit sha0t"
tubines can un J di00eent s!eeds

%"6 )5haust .$stem
Sim!le Cycle Stac5
Tansition to HRS*
%"! #u5iliar$ components o' gas tur4ine
Thee ae main thee au:iliay com!onents o0 gas tubine ae:
*as tubine state
Inlet ai 0ilte
?in; 0an ai coole
19
%"!"1 /as tur4ine starter
The gas tubine eIuies a stating mechanism to s!in the main sha0t initially" and once the tubine eaches its
ated s!eed this mechanism detaches automatically$ This stating !ocess nomally uses an electic moto to s!in
the main tubine sha0t$ The moto is bolted to the outside o0 the engine and uses a sha0t and geas to connect to
the main sha0t$ The electic moto s!ins the main sha0t until thee is enough ai blo4ing though the com!esso
and the combustion chambe to light the tubine$ ?uel stats 0lo4ing and an ignite simila to a s!a5 !lug ignites
the 0uel$ Then 0uel 0lo4 is inceased to s!in the engine u! to its o!eating s!eed
20
?ig$ 9$< Au:iliay systems o0 gas tubine
%"8 IN,)T #IR FI,T)R.
21
The ai su!!lied to the gas tubine must be cleaned and conditioned thooughly and no im!uities" dust and
coosi#e chemicals should be !esent in it$ ?o this !u!ose the atmos!heic ai is !assed though ai 0ilte
house that contains a numbe o0 small cylindical 0iltes$
%"8"1 #IR FI,T)R *-0.)
?ig$ 9$> Ai 0ilte house
#IR FI,T)R.
?ig$ 9$' Ai 0iltes
A0te this the ai is !assed though 0in 0an ai cooles and ai 4ashe system 0o contolling the tem!eatue and
then to the tubine

22
%"9 F#N #IR C--,)R.
*as tubines o!eate 4ith a constant #olume o0 ai 0lo4" but the !o4e they geneate is detemined by the mass
0lo4 o0 ai$ As a esult" the dense the ai is 4hen it 0lo4s though the tubine" the geate that the out!ut !o4e
4ill be$ .am ai is less dense than cold ai" and thee0oe gi#es a lo4e !o4e out!ut$ In addition" 4am ai is
hade to com!ess than cold ai" thus eIuiing geate 4o5 0om the com!esso" lea#ing less net a#ailable
sha0t enegy$
?ig$ 9$%& ?an Ai cooles
23
C*#PT)R =
.T)#( T0R+IN) .)CTI-N
?ig =$% Steam tubine
24
A steam tur4ine is a mechanical de#ice that e:tacts themal enegy 0om !essui6ed steam" and con#ets it
into use0ul mechanical 4o5$ The a#ailable heat enegy o0 the steam 0ist is con#eted into 5inetic enegy by the
e:!ansion o0 the steam in suitably sha!ed !assage" o no66le" 0om 4hich it issues as a Bet" at a !o!e angle"
against cu#ed blades mounted on a e#ol#ing dis5 o cylinde and by the eaction o0 the Bet itsel0 as it lea#es
the cu#ed !assage$ The !essue on the blades" causing otay motion" is solely due to the change o0
momentum o0 the steam Bet duing its !assage though these blades$
?ig$ =$9 Steam Tubine blading
The steam enegy is con#eted mechanical 4o5 by e:!ansion though the tubine$ The e:!ansion ta5es !lace
though a seies o0 0i:ed blades 1no66les3 and mo#ing blades each o4 o0 0i:ed blades and mo#ing blades is
called a stage$ The mo#ing blades otate on the cental tubine oto and the 0i:ed blades ae concentically
25
aanged 4ithin the cicula tubine casing 4hich is substantially designed to 4ithstand the steam !essue$ ,n
lage out!ut tubines the duty too lage 0o one tubine and a numbe o0 tubine casingHoto units ae combined
to achie#e the duty$ These ae geneally aanged on a common cente line 1tandem mounted3 but !aallel
systems can be used called coss com!ound systems$
&"1 1-R2IN/ C3C,)
The steam tubine 4o5s on an5ine cycle" the Ran:ine c$cle is a themodynamic cycle 4hich con#ets heat
into 4o5$ The heat is su!!lied e:tenally to a closed loo!" 4hich usually uses steam as the 4o5ing 0luid$ A
Ran5ine cycle descibes a model o0 the o!eation o0 steam heat engines most commonly 0ound in !o4e
geneation !lants$ Common heat souces 0o !o4e !lants using the Ran5ine cycle ae coal" natual gas" oil" and
nuclea$
&"% PR-C)..). IN R#N2IN) C3C,);
?ig$ =$= !ocesses in Ran5ine cycle
Process 1-%: The 4o5ing 0luid is !um!ed 0om lo4 to high !essue" as the 0luid is a liIuid at this stage the
!um! eIuies little in!ut enegy$
26
Process %-&: The high !essue liIuid entes a boile 4hee it is heated at constant !essue by an e:tenal heat
souce to become a dy satuated #a!o$
Process &-: The dy satuated #a!ou e:!ands though a tubine" geneating !o4e$ This deceases the
tem!eatue and !essue o0 the #a!ou" and some condensation may occu$
Process -1: The 4et #a!ou then entes a condense 4hee it is cooled at a constant !essue and tem!eatue
to become a satuated liIuid$ The !essue and tem!eatue o0 the condense is 0i:ed by the tem!eatue o0 the
cooling coils as the 0luid is undegoing a !hase;change$
&"& C-N.TR0CTI-N#, F)#T0R).
The steam tubine at 2$2$C$/ has a tandem com!ound sha0t aangement 4ith H$2 and /$2 section
&"&"1 *"P tur4ine;
The H$2 tubine is o0 single 0lo4" double shell constuction 4ith hoi6ontally s!lit casings allo4ance is made
0o themal mo#ement o0 the inne casing 4ithin the oute casing$ The main steam entes the inne casing 0om
to! and bottom$
&"&"% ,"P tur4ine;
The casing o0 the double 0lo4 /$2 tubine is o0 thee shell design$ The shells ae o0 hoi6ontally s!lit 4elded
constuction$ The inne casing 4hich caies the 0ist o4s o0 stationay blades is su!!oted on the oute casing
so as to allo4 0o themal e:!ansion$

27
&"&"& +,#DIN/

?ig =$) Blading
The entie tubine is !o#ided 4ith eaction blading$ The mo#ing blades o0 H$2 tubine and the initial o4s o0
/$2 tubine 4ith in#eted T oots and integal shouding ae machined 0om solid ectangula ba$
&"&" +)#RIN/.
The H$2 oto is su!!oted on t4o beaings a combined Bounal and thust beaing at its 0ont and a Bounal
beaing close to the cou!ling 4ith /$2 moto$ The /$2 oto has a Bounal beaing at its end$ The combined
Bounal and thust beaing ta5es u! esidual thust 0om both diections
28
&"&"7 .*#FT /,#ND #ND INT)R.T#/) .)#,IN/:
The sha0t gland seals the steam inside the cylindes against atmos!hee and the intestage seals estict lea5age
at blade ti!
$
?ig$ =$( Sha0t gland and intestage sealing
29
&"&"6 <al=es; Steam entes the tubine 0om the HRS* into a seies o0 #al#es$ These #al#es ae contolled
by the go#eno 4ith egulates the amount o0 steam !assing though the tubine in ode to maintain the constant
s!eed eIuied to geneate !o4e at (& cycles !e second$
?ig$=$7 #al#es
&" Tur4ine go=erning s$stem
30
The tubine has an electo;hydaulic go#ening system bac5ed u! 4ith a hydaulic go#ening system$
Anelectic system measues and contols s!eed" out!ut and o!eate the contol #al#es hydaulically in
conBunction 4ith an electo; hydaulic con#ete$
&"7 Tur4ine monitoring s$stem
In addition to the measuing instuments and instuments indicating !essues" tem!eatues" #al#es !ositions
and s!eed" the monitoing system also includes measuing instuments and indicatos 0o the 0ollo4ing #alues:
Di00eential e:!ansion bet4een the sha0ting and tubine casing$
Beaing !edestal #ibations" measued at all tubine beaings$
Relati#e sha0t #ibations measued at all beaings$
?ig$ =$< Tubine motoing system
&"6 Technical speci'ication;
31
H$2 tubine : Single 0lo4 4ith 9> eaction stages$
/$2 tubine : Double 0lo4 4ith > eaction stages$
Main sto! and contol #al#es : 9
/$2 sto! and contol #al#es : 9
S!eed:;
Rated S!eed : (&$&Hs
Ma:$ S!eed no time limitation : (%$(Hs
Min s!eed no time limitation : )<$(Hs
R)F)R)NC)
Boo5s at 22S;% /IBRARA$
Intenet
32