Industrial Training Report On NTPC DADRI

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JUNE - JULY
2009
Industrial Training Report
SUBMITTED BY:
DIGVIJAY SINGH MECHANICAL (FINAL YR.) ROLL NO. 0621640015
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INDUSTRIAL TRAINING REPORT ON ‘ NTPC DADRI’
GAS POWER PLANT
National Thermal Power Corporation Limited National Capital Power Station - Dadr
i P .O. Vidyut Nagar, District Gautam Budh Nagar - 201 008 (UP)
“NTPC was set up in the central sector in the 1975.Only PSU to achieve excellent r
ating in respect of MOU targets signed with Govt. of India each year. NTPC Dadri
station has also bagged ISO 14001 certification. Today NTPC contributes more th
an 3 / 5th of the total power generation in India .”
INDUSTRIAL TRAINING REPORT BY DIGVIJAY SINGH Email Id- singh_digvijay89_yahoo.in
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CONTENTS
S.NO . DESCRIPTION
(1) (2) (3) OVE RVIE W OF NTP C SATIO N AT A GL AN CE INTR ODU CT IO N T O GAS P
OWER PLANT GAS TU RB IN E STARTI NG SYSTEM FUEL SY STEM SA LIE NT FEA TU RES OF
NTP C DADR I GAS PLA NT OPE RATIO N HOW DOES A CO MB INED CYCLE PO WE R PLA NT W
OR K? AUT OMA TI ON AN D CON TR OL
PAGE NO . 3 5
6
(4)
17
(5) (6)
19 25
(7) (8)
26 30
(9)
46
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(i) Overview of NTPC
NTPC was set up in the central sector in the 1975 in response to widening demand
& supply gap with the main objective of planning, promoting & organizing an int
egrated development to thermal power in India. Ever since its inception, NTPC ha
s never looked back and the corporation is treading steps of success one
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after the other. The only PSU to have achieved excellent rating in respect of MO
U targets signed with Govt. of India each year. NTPC is poised to become a 40,00
0 MW gint corporation by the end of XI plan i.e. 2012 AD. Lighting up one fourth
of the nation, NTPC has an installed capacity of 19,291 MW from its commitment
to provide quality power; all the operating stations of NTPC located in the Nati
onal Capital Region & western have acquired ISO 9002 certification. The service
groups like Engineering, Contracts, materials and operation Services have also b
agged the ISO 9001 certification. NTPC Dadri, Ramagundam, Vindhyachal and Korba
station have also bagged ISO 14001 certification. Today NTPC contributes more th
an 3 / 5th of the total power generation in India.
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(ii) Station At Glance
NTPC dadri is model project of NTPC . also it tit the best project of NTPC also
known as NCPS ( National capital power station ). Situated 60 kms away from Delh
i in the District of gautam budh Nagar, Uttar Pradesh. The station has an instal
led capacity of 1669 MW of power – 840 MW from Coal based units and 829 MW Gas Bas
ed Station . the station is excelling in performance ever since it’s commercial op
eration . consistently in receipts of meritorious projectivity awards, the coal
based units of the station stood first in the country in terms of PLF for the fi
nancial year 1999 – 2000 by generating an all time national high PLF of 96.12 % wi
th the most modern O & M Practices. NTPC – Dadri is committed to generated clean a
nd green Power. The Station also houses the first HVDC station of the country (G
EP project) in association with centre for power efficiency and Environment & US
AUID. The station has protection (CENEEP) – NTPC
bagged ISO 14001 & ISO 9002 certification during the financial year 1999 – 2000, c
ertified by Agency of International repute M/s DNV Netherlands M/s DNV Germany r
espectively
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1.Introduction To Gas Power Plants
Introduction
The development of the sector in the country, since independence has been predom
inantly through the State Electricity Boards. In order to supplement the effects
of the states in accelerating power development and to promote power developmen
t on a regional basis to enable the optimum utilisation of energy resources, the
Government of India decided to take up a programme of establishment of large hy
dro and thermal power stations in the central sec tor on a regional basis. With
this in view, the Government set up the National Thermal Power Corporation Ltd.,
in November 1975 with the objective of planning, construction, commissioning, o
peration and maintenance of Super Thermal and Gas Based Power projects in the co
untry. The availability of gas in a large quantity in western offshore region ha
s opened an opportunity to use the gas for power generation, which is an economi
cal way and quicker method of augmenting power generating capacity by natural ga
s as fuel in combined cycle power plant in a power deficit country like ours. Wi
th this intention in mind the Government asked
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NTPC to take up the construction of Kawas, Auraiya, Anta, Dadri and Gandhar Gas
Power Project along the HBJ Gas pipe line. The power plant consists of gas turbi
ne generating units waste heat recovery boilers, steam turbo generator, ancillar
y electrical and mechanical equipments. The power generated at this power statio
n is fed over 220 KV AC transmission system associated with this project to dist
ribute the power in the various Regions. In the Power Sector, gas turbine drive
generators are used.
Gas turbines range in size from less than 100 KW up to about 140.000 KW. The gas
turbine has found increasing application due to the following potential advanta
ges over competive equipment. • Small size and weight per horsepower • Rapid loading
capability • Self-contained packaged unit • Moderate first cost • No cooling water re
quired • Easy maintenance • High reliability • Waste heat available for combined cycle
application. • Low Gestation Period • Low Pollution Hazards The function of a gas t
urbine in a combined cycle power plant is to drive a generator which produce ele
ctricity and to provide
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input heat for the steam cycle. Power for driving the compressor is also derived
from gas turbine.
Combined Cycle
Combined Cycle power plant integrates two power conversion cycles namely. Brayto
n Cycle (Gas Turbines) and Rankin Cycle (Conventional steam power plant) with th
e principal objective of increasing overall plant efficiency.
Brayton Cycle
Gas Turbine plant-operate on Brayton Cycle in which air is compressed this compr
essed air is heated in the combustor by burning fuel combustion produced is allo
wed to expand In the Turbine and the turbine is coupled with the generator. With
out losses the theoretical cycle process is represented by 1’ 2’ 3’ 4’ In the actual pro
cess losses do occur. Deviation from the theoretical process, results from the f
act that compression and expansion are not performed isentropically but polytrop
ically which is conditioned by heat dissipation (expansion) and heat supply (Com
pression) caused
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by various flow and fraction by losses. In the combined cycle mode, the Brayton
Cycle is chosen as the topping cycle due to the high temperature of the exhaust
of the gas turbine (point 4 in the P.V diagram). In modern gas turbines the temp
erature of the exhaust gas is in the range of 500 to 550 0C. Reference to the T.
S. diagram may indicate the amount of heat that is produced, converted into mech
anical energy and extracted from this process. For the evaluation of the cyclic
process, two parameters are of greatest importance; 1) Thermal efficiency 2) Pro
cess working capacity
Thermal efficiency is obtained from chemical binding energy of the fuel and mech
anical energy available at the shaft of the gas turbine. Thermal efficiency ( th
) as follows:
th
= Energy at GT shaft Chemical Energy of fuel = (Q Input. Q output )/ Q Input = 1
— Q Output/ Q Input
Working capacity is also obtained from the difference between
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the amounts of heat supplied and removed. This is achieved by increasing P2 that
is increasing gas inlet temperature T3.
Fig.1
Rankine Cycle
The conversion of heat energy to mechanical energy with the aid of steam is carr
ied out through this cycle. In its simplest form the cycle works as follows (fig
.2). The initial state of the working fluid is water (point-3) which, at
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a certain temperature is compressed by a pump (process 3-4) and fed to the boile
r. In the boiler the compressed water is heated at constant pressure (process 4-
5-6-1). Modern steam power plants have steam temperature in the range of 500 0C
to 550 0C at the inlet of the turbine.
Fig.2
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Combining two Cycles to Improve Efficiency
We have seen in the above two cycles that gas turbine exhaust is at a temperatur
e of 500–550 0C and in Rankine Cycle heat is required to generate steam at the tem
perature of 500-550 0C. so, why not use the gas-turbine exhaust to generate stea
m in the Rankine cycle and save the fuel required to heat the water ? Combined C
ycle does just the same. The efficiency of Gas Turbine cycle alone is 30% and th
e efficiency of Rankine Cycle is 35%. The overall efficiency of combined cycle c
omes to 48%.
Types of Combined Cycles
It is basically of two types, namely Unfired Combined cycle and Fully Fired comb
ined cycle.
Unfired combined Cycle
The basic system is shown in figure- 3. in this system the exhaust gas is used o
nly for raising steam to be fed to the steam turbine for power generation.
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The conventional fossil fuel fired boiler of the steam power plant is replaced w
ith a ‘Heat Recovery Steam Generator’ (HRSG). Exhaust gas from the gas turbine is le
d to the HRSG where heat of exhaust gas is utilised to produce steam at desired
parameters as required by the steam turbine. However, non-reheat steam turbine i
s the preferred choice for adopting this type of system as usually the live stea
m temperature for HRSG will be solely controlled by the gas turbine exhaust temp
erature which is usually around 500 0C.
UNFIRED COMBINED CYCLE FIG-3
In recent development, with the introduction of Dual Pressure Cycles more heat i
s recovered in the HRSG and steam with higher pressure and temperature can be ge
nerated. But higher
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capital investment and sometimes necessity of supplemental firing system makes t
he system complex and costly.
Fully Fired Combined Cycle
Fig – 4 shows the basic schematic of this cycle. In this system the heat of exhaus
t gas from gas turbine is used for two purposes as described below: Heat contain
ed in exhaust gas is used to heat feed water to a desire
BOILER REPOWERING EXCHANGER
SYSTEM
EXHAUST
HEAT
Fig. 4
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temperature at the inlet to the boiler. This leads to the reduction or eliminati
on of the extraction steam requirement from the steam turbine. In case, the stea
m turbine has a larger steam swallowing capacity to generate more power the amou
nt of steam which is being extracted from steam turbine for regenerative feed he
ating could be made to expand in the turbine to increase its base load capacity
and improve the overall efficiency. In case the steam turbine does not have the
capacity to swallow extra steam available due to cutting down of extraction, the
fuel being fired in the boiler can be cut down to generate less steam by an amo
unt equivalent to steam required for extractions and thus improving the overall
efficiency due to less consumption of fuel. Gas turbine exhaust contains about 1
4 to 16 % oxygen (by weight) and can be used as hot secondary air in the convent
ional fossil fired furnaces. So the heat required to heat the secondary air will
be saved and can be used for other purposes. FD fan power consumption will also
be reduced to a great extent.
Fuels
Gas turbines are capable of burning a range of fuels including naptha, distillat
es, crude oils and natural gas. Selection of fuel (s)
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depends on several factors including fuel availability, fuel cost and cleanlines
s of fuel. Natural gas is an ideal fuel because it provides high thermal efficie
ncy and reliability with a low operation and maintenance cost. Liquid fuels, par
ticularly heavy oils, usually contain contaminants, which cause corrosion and fo
uling in the gas turbine. Contaminants, which cannot be removed from the fuel, m
ay leave deposits in the gas turbine, which reduce performance and add maintenan
ce costs. Dual fuel systems are commonly used, enabling the gas turbine to burn
back-up fuels when the primary fuel source is not available. Dual fuel systems c
an also be designed to fire both fuels simultaneously.
Advantages Plants
of
Combined
Cycle
Apart from the higher overall efficiency, the combined cycle power plants have f
ollowing advantages: Low installation Cost: power from a combined cycle power pl
ant is approximately 70% of a conventional coal based power plant of same capaci
ty.
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Low Gestation Period: Power from a combined cycle power plant can be obtained in
two phases, i.e. two third power, obtainable from gas turbines, is available wi
thin 16-18 months and the balance in next 1 month. This is much lower than the g
estation period for conventional thermal power plants, which is around 48-60 mon
ths. Better Reliability: Combined cycle power plants are considered to be highly
reliable with the reliability factor of 85-90% as compared to 60-65% for conven
tional coal Fired Power Plants.
2. Gas System
Turbine
Starting
The function of the starting system is to crank the gas turbine upto the require
d speed until : it becomes self sustaining. One method of starting large gas tur
bine is by using a motor driven hydraulic starting system. Alternatively, the GT
G can be started by using a frequency converter to rotate the generator which dr
ives the turbine for starting. A typical hydraulic starting system for each gas
turbine consist of the following:
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• Starting motor, electric AC induction motor • Hydraulic torque converter • Auxiliary
Gear • Couplings The electric starting motor drives the hydraulic torque generato
r through a coupling. The hydraulic torque converter consists of an impeller, wh
ich forces the fluid against hydraulic starting motor. The hydraulic torque conv
erter is coupled to the accessory gear, which is connected to the gas turbine sh
aft. The torque converter receives hy draulic fluid from hydraulic and lube oil
reservoir during operation. When gas turbine reaches self-sustaining speed the s
tarting device is disconnected and shut down. To break the inertia of the starti
ng motor and reduce the starting current a pony motor is provided. Gas turbines
of GE and WH designs are provided with starting motor system for cranking purpos
e. The static frequency converter serves the same function of starting, accelera
ting running at preset speed by starting the generator as a synchronous motor by
feeding variable frequency current drawn from the connected grid. Gas turbines
of ABB and SIEMENS make are provided with frequency converter s for the GT crank
ing and normally 2 * 100% static converters are provided for the power station.
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Black Start System
To start a gas turbine in the event of AC-power failure an emergency black start
system is provided. It also helps in safe coasting down of the gas turbine and
its auxiliaries following a ‘trip’ in the event of grid collapse. The black start sy
stem consist of a separate diesel engine or a gas turbine driven synchronous gen
erator connected to station switch gear bus. It can be operated manually from lo
cal or remote and also it automatically comes into operation following a black o
ut condition. Capacity of the black start unit should be such that it can supply
the total auxiliary power required to start a gas turbine from standstill condi
tion. The NTPC’s Auraiya project gas turbine is provided for emergency black-start
purpose and all other projects are provided with diesel generator set for the s
ame duty.
3. Fuel System
Fuel System of Gas Turbine
The function of the fuel system is to deliver fuel to the
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combustion chamber(s) of a gas turbine at quantity and pressure as required by t
he control system
Liquid fuel system
The liquid fuel system consists of the liquid fuel storage and handling system.
The liquid fuel storage and handling system provides means for unloading , stora
ge and distribution of the fuel oil within the plant and typically composed of t
he following major components: • • • • • • • Fuel oil unloading pumps Fuel oil transfer pum
Fuel oil storage tanks Flow meter Strainers Pressure and Level control stations.
Distribution piping
The number and size of equipments is site dependant. The storage facility is dep
endant on such factors as the location of the site, proximity of the oil supply
and the reliability of the oil supply. Fuel oil may be supplied to the plant by
a pipeline, oil barriages, oil tankers, rail/road or high way trucks. Fuel oil u
nloading pumps may not be required if the oil arrives by a pipeline, an oil barg
e, or an oil tanker since they have their own pumps.
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Naphtha Pressurising System
By the forwarding pumps,Naptha is pumped upto the GTs and kept under recirculati
on. For firing the naphtha is the GT,separate pressurising system with high pres
sure pump, allied filters and m easurements and recirculation system is used. Th
is pressurising is required because in the naphtha burner this fuel is mechanica
lly atomised. There is no other medium like air, etc are used for atomisation.
Naphtha drain system
Since the flash/fire point of this fuel is very low it is designed to drain the
oil from the piping burner etc when the system is stopped. Separate drain tanks
are kept at pumping stations, which will collect these naphtha and pump back to
the main storage tanks.
Mode of firing
It is provided to fire natural gas or naphtha or in mixed mode of the fuel in th
e GT Combustion Chamber.
FUEL GAS SYSTEM
The purpose of the fuel gas system is to take gas fuel from the custody transfer
point, process it to the quality and pressure conditions required by the gas tu
rbine and to distribute it and
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monitor its use. Fuel gas system consists of the off base system and the on base
system. Off base fuel gas System The off-base fuel gas system is typically comp
osed of the following major components: • An emergency stop valve at the gas inlet
to the plant knock out drum • Filters • Pressure-control station • Distribution pipin
g Optional Components are • Gas metering station • Gas Heaters The need for any of t
he optional components is dictated by the conditions specific to each individual
application. The final supply pressure required at gas turbine is a function of
the gas turbine compression ratio and the control valve and nozzle pressure dro
ps. Large gas turbines typically require a gas supply pressure of about Kg/cm2 w
ith pressure regulated with in +10 percent off-set point. The emergency stop val
ve at the in let to the station is provided to completely shut off the gas suppl
y in an emergency. The gas
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fuel then goes through a knockout drum. A knock out drum will remove the free li
quid and some solids from the gas stream. However, it will not separate out much
of the entrained liquids. The liquids separation from gas stream takes place by
decreasing the gas veloc ity in its transit through the drum. Impurities collec
t at the drum bottom and are periodically automatically purged A level controlle
r opens a drain valve which allows the waste to Adrian tank vented to the atmosp
here. The filter separators must have minimum of two stages of separation. The i
nitial stage being utilised removal of large liquid droplets and the final stage
for mist separation. Any solid particles carried with the gas stream are separa
ted in the first stage . The first stage elements consist of hollow tubes of gla
ss fibers through which gas flows radially from outside. The separation of carri
ed solids and liquid particles is by interception, diffusion and/or inertial imp
action of the droplets on the fibers. The liquid droplets coalesced on the surfa
ce drain on to the shell and from there to the drain pot. The second stage mist
separator is preferably of the vans type in which liquid separation takes place
by subjecting the gas path to multiple changes of direction. The gas analysis is
carefully checked from the stand point these point of hydrate formation or icin
g at the pressure reducing station under the worst ambient temperatures prevalen
t at each site. If there is any tendency for the above, a suitably, rated gas fi
red indirect heater is provided ahead of the pressure reducing station. The gas
heater ensures a gas temperature sufficiently high such that the after pressure
reduction the gas temperature is at least 20” C higher than hydrate forming temper
ature or the gas dew point whichever is higher. The heater normally utilises
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natural gas for firing. Heat from the fire tube be utilised to heat a water bath
in which the U tubes for carrying the gases to be heated are immersed. The cont
rol system ensures constant temperature of the outlet gas for gas flows ranging
from zero to full gas flow. A full capacity bypass is provided so as to enable o
peration of the fuel gas system is designed to deliver gas fuel to the gas turbi
ne combustion chamber(s) at the proper pressure and flow rates to meet all the s
tarting, acceleration and loading requirements of gas turbine operation.
Naphtha forwarding system
The forwarding system is mainly remote controlled from the GT LCR and CCR. Altho
ugh there is a possibility to control the main devices locally by a switching th
e selector switch on local position in the local panel. By means of three way va
lves a tank selection is possible. To ensure the standby position of the lines k
eep the value open. The pumps are protected by the automatic recirculating valve
s. The condition of the strainers as well as of the filters is monitored by the
differential pressure indicators and switches. The safety valves protect the lin
e against the line against over pressure.
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4. Salient Features Of NTPC DADRI Gas Project
DADRI GBCCPP-STAGE I (817MW) General Layout Plan In the main plant block two mod
ules, each consisting of two GTGs placed on each side of 2 STGs. The central con
trol room is located towards west of the ST hall. The transformer yard Is on the
wester side of the turbine hall, with switchyard further down west. Induced dra
ft cooling towers have been located considering the proper flow of cooling water
. Nearer to main power house & convenient routing of open return channel to CW p
ump house. The 220/400 KV switchyard has been located in front of the power stat
ion. The 220 KV switchyard control room is accommodated in the central control r
oom itself. Space has been kept for liquid oil installation and oil unloading fa
cilities. The GAIL terminal for receiving gas is located within
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boundary of plant site.
5. Gas Plant Operation
Gas Turbine, WHRB, Turbine Starting Modes Steam
Basic conditions for plant operation are as follows:• Start up or shut down of G/T
, WHRB and S/T of each module is performed separately from the other module (exc
ept for S/T gland steam back-up and heating steam back up systems). • Start up/shu
t down mode is selected freely form among those mentioned. The start up/shut dow
n procedure for WHRB and S/T here mainly describes operating procedure for G/T b
ypass damper, WHRB inlet damper and remote operated valve necessary for start up
and shut down from G/T exhaust gas admission to WHR till rated load operation o
f S/T. For detail operating procedure for G/T WHRB, S/T auxiliaries and remote o
perated valve following procedures are followed.
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Start up Mode
The start up mode of G/T, S/T and WHRB shall be selected from among the followin
g as a rule through various other start up modes are conceivable according to po
wer demand and operating principle.
Outline of each start up
• Normal start up mode This mode is two unit (2G/T’s + 2WHRB’s +1 S/T) combined cycle
start up mode which, after starting up one each of G/T and WHRB, starts up the o
ther G/T and WHRB and brings the output of G/T and S/T the target output of the
module. In this mode, S/T is loaded with one each of G/T and WHRB in operation,
and after the initial load is achieved, the pressure control of HP/LP by-pass va
lves of both WHRB’S is changed to common pressure control and then S/T is loaded u
p. The timing of starting up the other G/T and WHRB is left to the discretion of
the operator, and S/T is kept stand by at the initial load until the pressure c
ontrol of both WHRB’S is changed to the common pressure control.
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• Rapid start up mode This is a mode of starting up both G/T’s and WHRB’S at the same
time, changing the pressure control of HP/LP by-pass valves of both WHRB’S to the
common pressure control, then loading up and brining G/T the output of and S/T t
o the target output of the module is achieved. This mode is used only for start
up after right stop or hot start up (with vacuum). In other start up modes; in w
hich the time from G/T start up to S/T loading is long, simultaneous startup is
not made to reduce heat lose at start up. • G/T/WHRB additionally start up mode Th
is is a mode of starting up the other G/T and WHRB one until combined cycle of G
/T, WHRB and S/T is in operation. In this mode, the HP Steam pressure and temper
ature of the other G/T and WHRB are raised up those of G/T and WHRB in operation
, and then the pressure control of HP/LP by-pass valves is changed to the common
pressure control, and S/T is loaded up.
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• Single G/T/WHRB start up mode This is a combined cycle start up mode of starting
up S/T with only one each of G/T and WHRB in operation. The other G/T and WHRB
remain stopped. • Individual pressure control Individual pressure control means pr
essure control made automatically by using HP/LP by-pass valves of both WHRB’s and
detecting pressure before HP/LPCV so that HP/LP steam pressure of both WHRB’S wil
l be the same and constant respectively. • Loading of S/T S/T loading rate after H
P/LP by-pass are fully closed and HP/LPCV are fully opened is determined by the
load change rate of G/T, namely S/T load change rate increases as G/T load chang
e rate increase. (Except for G/T/WHRB additionally start up mode). S/T unloading
rate too is determined by G/T load change rate under HP/LP by-pass valves are f
ully closed and HP/LPCV are fully opened.
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6.How Does A Combined-Cycle Power Plant Work?
Power Generation:
Air Inlet The amount of air needed for combustion is 800,000 cubic feet per minu
te. This air is drawn though the large air inlet section where it is cleaned, co
oled and controlled, in order to reduce noise.
Turbine-Generators:
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The air then enters the gas turbine where it is compressed, mixed with natural g
as and ignited, which causes it to expand. The pressure created from the expansi
on spins the turbine blades, which are attached to a shaft and a generator, crea
ting electricity. Each gas turbine produces 185 megawatts (MW) of electricity. T
he blades are attached to a rotor, which spins the generator, and makes electric
ity. Think of a generator as a huge spinning magnet inside a coil of wire. As th
e magnet spins, electricity is created in the wire loops.
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Heat
Recovery
Steam
Generator
(HRSG) • The hot exhaust gas exits the turbine at about 1100 degrees Fahrenheit an
d then passes through
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the Nooter Erickson, Heat Recovery Steam Generator (HRSG). In the HRSG, there ar
e 18 layers of 100-foot tall tube bundles, filled with high purity water. The ho
t exhaust gas coming from the turbines passes through these tube bundles, which
act like a radiator, boiling the water inside the tubes, and turning that water
into steam. The gas then exits the power plant through the exhaust stack at a mu
ch cooler 180 degrees, after having given up most of its heat to the steam proce
ss. About 1 million pounds of steam per hour is generated in this way and sent o
ver to the steam turbine through overhead piping. Steam Turbine
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The steam turbine is a Siemens Westinghouse KN Turbine Generator, capable of pro
ducing up to 240 MW. It is located on top of the condenser, across from the cool
ing tower. Steam enters the turbine with temperatures as high as 1000 degrees Fa
hrenheit and pressure as strong as 2,200 pounds per square inch. The pressure of
the steam is used to spin turbine blades that are attached to a rotor and a gen
erator, producing additional electricity, about 100 megawatts per HRSG unit. Aft
er the steam is spent in the turbine process, the residual steam leaves the turb
ine at low pressure and low heat, about 100 degrees. This
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exhaust steam passes into a condenser, to be turned back into water. By using th
is “combined-cycle” process, two gas turbines and one steam turbine, we can produce
a total of about 600 megawatts of electricity. Emissions Control Selective Catal
ytic Reduction (SCR) To control the emissions in the exhaust gas so that it rema
ins within permitted levels as it enters the atmosphere, the exhaust gas passes
though two catalysts located in the HRSG. One catalyst controls Carbon Monoxide
(CO) emissions and the other catalyst controls Oxides of Nitrogen, (NOx) emissio
ns.
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Aqueous Ammonia
In addition to the SCR, Aqueous Ammonia (a mixture of 22% ammonia and 78% water)
is injected into system to even further reduce levels of NOx.
Best Available Control Technology (BACT)
Our annual average concentration of NOx is only 2 parts per million, which is co
nsidered the “best available control technology” or BACT by the Air Board.
As exhaust gas passes out of the exhaust stack, it is continuously sampled and a
nalyzed, assuring that permit limits are being met.
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With this kind of clean, modern technology, the exhaust stack is only 145 feet h
igh, compared to 500 feet, the height required by older power plants that use le
ss efficient emission technology. Environmental and health organizations recogni
ze this technology as a benefit to the community. The local chapters of the Amer
ican Lung Association and Sierra Club both support the Metcalf Energy Center.
Transmission Onto the Grid Transformers
of
Generated
Power
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The Gas Turbine and Steam Turbine generators produce power at 13,000 volts. The
transformers take the generated 13,000 volts and “transform” them to 230,000 volts,
which is the required voltage needed for transmission to the nearby tower that s
ends power to the substation. A small amount of generation is directed to “Auxilia
ry transformers” which “transform” the generated voltage to a lower voltage, so it may
be used by the plant to power our own pumps, fans, and motors. The Metcalf Ener
gy Center requires 12 – 15 megawatts to operate. Switchyard From each transformer,
the power passes underground into our switchyard. The power
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from all of the generators comes together there, where it is measured, metered a
nd directed onto the grid. The proximity of the site to a large, existing PG&E s
ubstation makes it a good place to build a power plant and the nearest transmiss
ion tower is only about 200 feet away. Condenser and Cooling Tower The purpose o
f the condenser is to turn low energy steam back into pure water for use in the
Heat Recovery Steam Generator. The purpose of the cooling tower is to cool the c
irculating water that passes through the condenser. It consists of ten cells wit
h large fans
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on top, inside the cone-like stacks, and a basin of water underneath. We process
and treat the Title 22 recycled water after receiving it from the City, before
using it in our cooling tower. The cool basin water absorbs all of the heat from
the residual steam after being exhausted from the steam turbine and it is then
piped back to the top of the cooling tower. As the cool water drops into the bas
in, hot wet air goes out of the stacks. Normally, hot moist air mixes with coole
r dry air, and typically a water vapor plume can be formed, one that may travel
hundreds of feet in the air and be seen from miles away. The California Energy C
ommission considered this visually undesirable in this community so we added a “Pl
umeINDUSTRIAL TRAINING REPORT BY DIGVIJAY SINGH Email Id- singh_digvijay89_yahoo
.in
P a g e | 44
Abatement” feature, louvers along the topsides of the tower that control the air f
low.
The cooling tower evaporates about three-fourth of the processed, recycled water
, then we send about one-fourth of it back through the sewer lines for re-treatm
ent by the City.
The Metcalf Energy Center purchases 3 to 4 million gallons per day of recycled w
ater from the City of San Jose. Evaporation of this water assists the City in ad
hering to their flow cap limits and helps to protect the sensitive saltwater mar
sh habitat of the San Francisco Bay environment from receiving too much fresh, r
ecycled water.
P a g e | 45
Water Tanks, Natural Gas Pipeline, Control Room Water Tanks The largest tank is
the Service Water tank. It contains 470,000 gallons of water to be used for drin
king, fire fighting and for the high purity water train. The water from the serv
ice water tank is pumped to the water treatment building where it then passes th
rough a reverse osmosis unit, a membrane decarbonater, and mixed resin bed demin
eralizers to produce up to 400 gallons per minute of ultra pure water. The pure
water is then stored in the smaller 365,000-gallon tank until it is turned into
steam for making electricity.
P a g e | 46
Natural Gas Natural gas fuels the combustion turbines. Each turbine can consume
up to 2,000 MMBTU per hour. The fuel comes from the major high pressure natural
gas pipeline that runs along the east side of Highway 101, less than 1 mile to t
he east of our site. During construction, “Horizontal Directional Drilling” was util
ized with careful coordination with many local authorities. The pipeline was bui
lt 60 feet underground and passed under highways, creek, train tracks, and envir
onmentally sensitive areas.
P a g e | 47
The pipeline enters the site just behind the water tanks, where equipment regula
tes and measures the natural gas composition, flow and pressure. Gas compressors
pump the natural gas though the facilities’ fuel gas system where it is delivered
to the gas turbine and the HRSG duct burners at the proper temperature, pressur
e and purity.
Control Room From the control room, the plant operators monitor and operate the
facility, via the plant’s “Distributed Control System”, with the click of a mouse, vie
wing graphic representations of all MEC systems on various screens.
P a g e | 48
The system gives operators both audible and visual signals to keep them informed
of plant conditions at all times and to determine when preventative maintenance
is required.
7.AUTOMATION AND CONTROL SYSTEM
AUTOMATION: THE DEFINITION
P a g e | 49
The word automation is widely used today in relation to various types of applica
tions, such as office automation, plant or process automation. This subsection p
resents the application of a control system for the automation of a process / pl
ant, such as a power station. In this last application, the automation actively
controls the plant during the three main phases of operation: plant start-up, po
wer generation in stable or put During plant start-up and shut-down, sequence co
ntrollers as well as long range modulating controllers in or out of operation ev
ery piece of the plant, at the correct time and in coordinated modes, taking int
o account safety as well as overstressing limits.
P a g e | 50
During stable generation of power, the modulating portion of the automation syst
em keeps the actual generated power value within the limits of the desired load
demand. During major load changes, the automation system automatically redefines
new set points and switches ON or OFF process pieces, to automatically bring th
e individual processes in an optimally coordinated way to the new desired load d
emand. This load transfer is executed according to pre- programmed adaptively co
ntrolled load gradients and in a safe way.
AUTOMATION: THE BENEFITS
P a g e | 51
The main benefits of plant automation are to increase overall plant availability
and efficiency. The increase of these two factors is achieved through a series
of features summarized as follows:
Optimisation of house load consumption during plant start- up, shut-down and ope
ration, via:
Faster plant start-up through elimination of control errors creating delays. Fas
ter sequence of control actions compared to manual ones. Figures 1 shows the seq
uence of a rapid restart using automation for a typical coal-fired station. Even
a well- trained operator crew would probably not be able to bring the plant to
full load in the same time without considerable risks.
P a g e | 52
Co-ordination of house load to the generated power output.
Ensure and maintain plant operation, even in case of disturbances in the control
system, via:
Coordinated ON / OFF and modulating control switchover capability from a sub pro
cess to a redundant one. Prevent sub-process and process tripping chain reaction
following a process component trip.
Reduce plant / process shutdown time for repair and maintenance as well as repai
r costs, via:
Protection of individual process components against overstress (in a stable or u

nstable plant operation).
P a g e | 53
Bringing processes in a safe stage of operation, where process components are pr
otected against overstress
PROCESS STRUCTURE
Analysis of processes in Power Stations and Industry advocates the advisability
of dividing the complex overall process into individual sub-processes having dis
tinctly defined functions. This division of the process in clearly defined group
s, termed as FUNCTIONAL GROUPS, results in a hierarchical process structure. Whi
le the hierarchical structure is governed in the horizontal direction by the num
ber of drives (motorised valves, fans, dampers, pumps,
P a g e | 54
etc.) in other words the size of the process; in the vertical direction, there i
s a distinction made between three fundamental levels, these being the:
Drive Level Function Group Level Unit Level.
To the Drive Level, the lowest level, belong the individual process equipment an
d associated electrical drives. The Function Group is that part of the process t
hat fulfils a particular defined task e.g., Induced Draft Control, Feed Water Co
ntrol, Blooming Mill Control, etc. Thus at the time of planning it is necessary
to identify each function group in a clear
P a g e | 55
manner by assigning it to a particular process activity. Each function group con
tains a combination of its associated individual equipment drives. The drive lev
els are subordinate to this level. The function groups are combined to obtain th
e overall process control function at the Unit Level. The above three levels are
defined with regard to the process and not from the control point of view.
CONTROL SYSTEM STRUCTURE
The primary requirement to be fulfilled by any control system architecture is th
at it be capable of
P a g e | 56
being organized and implemented on true processoriented lines. In other words, t
he control system structure should map on to the hierarchy process structure. BH
EL’s PROCONTROL P®, a microprocessor based intelligent remote multiplexing system, m
eets this requirement completely.
SYSTEM OVERVIEW
The control and automation system used here is a micro based intelligent multipl
exing system This
P a g e | 57
system, designed on a modular basis, allows to tighten the scope of control hard
ware to the particular control strategy and operating requirements of the proces
s Regardless of the type and extent of process to control provides system unifor
mity and integrity for: Signal conditioning and transmission Modulating controls
CONTROL AND MONITORING MECHANISMS

There are basically two types of Problems faced in a Power Plant
P a g e | 58
Metallurgical Mechanical Mechanical Problemcan be related to Turbines that is th
e max speed permissible for a turbine is 3000 rpm , so speed should be monitored
and maintained at that level Metallurgical Problem can be view as the max Inlet
Temperature for Turbile is 1060 oC so temperature should be below the limit. Mo
nitoring of all the parameters is necessary for the safety of both: Employees Ma
chines
P a g e | 59
So the Parameters to be monitored are : Speed Temperature Current Voltage Pressu
re Eccentricity Flow of Gases Vaccum Pressure Valves Level Vibration PRESSURE M
NITORING
P a g e | 60
Pressure can be monitored by three types of basic mechanisms Switches Gauges Tra
nsmitter type
For gauges we use Bourden tubes : The Bourdon Tube is a non liquid pressure meas
urement device. It is widely used in applications where inexpensive static press
ure measurements are needed. A typical Bourdon tube contains a curved tube that
is open to external pressure input on one end and is coupled mechanically to an
indicating needle on the other end, as shown schematically below.
P a g e | 61
Typical Bourdon Tube Pressure Gages
Transmitter types use transducers (electrical to electrical normally) they are u
sed where continuous monitoring is required Normally capacitive transducers are
used
P a g e | 62
For Switches pressure swithes are used and they can be used for digital means of
monitoring as swith being ON is referred as high and being OFF is as low.
All the monitored data is converted to either Current or Voltage parameter.
P a g e | 63
The Plant standard for current and voltage are as under Voltage : 0 – 10 Volts ran
ge Current : 4 – 20 milliAmperes We use 4mA as the lower value so as to check for
disturbances and wire breaks. Accuracy of such systems is very high . ACCURACY :
+ - 0.1 % The whole system used is SCADA based
INPUT
4-20 mA
ANALOG INPUT MODULE MICRO PROCESSOR
P a g e | 64
ALARM
We use DDCMIC control for this process. Programmable Logic Circuits ( PLCs) are
used in the process as they are the heardt of Instrumentation.
Pressure Electricity AN D Level Level High High level Electricity OR
HL switch
Start low Pressure in line
LL switch
pump Stop Pressure
Electricity
BASIC PRESSURE CONTROL MECHANISM
P a g e | 65
Hence PLC selection depends upon the Criticality of the Process
TEMPERATURE MONITORING We can use Thernocouples or RTDs for temperature monitori
ng Normally RTDs are used for low temperatures. Thermocoupkle selection depends
upon two factors: Temperature Range Accuracy Required Normally used Thermocouple
is K Type
Thermocouple:
P a g e | 66
Chromel
(Nickel-Chromium
Alloy)
/
Alumel
(Nickel-Aluminium Alloy) This is the most commonly used general purpose thermoco
uple. It is inexpensive and, owing to its popularity, available in a wide variet
y of probes. They are available in the −200 °C to +1200 °C range. Sensitivity is appro
ximately 41 µV/°C. RTDs are also used but not in protection systems due to vibration
al errors. We pass a constant curre t through the RTD. So that if R changes then
the Voltage also changes RTDs used in Industries are Pt100 and Pt1000
INDUSTRIAL TRAINING REPORT BY DIGVIJAY SINGH Email Id singh_digvijay89_yahoo.in
P a g e | 67
Pt100 : 0 0C – 100 Ω ( 1 Ω = 2.5 0C ) Pt1000 : 0 0C - 1000Ω Pt1000 is used for higher ac
curacy The gauges used for Temperature measurements are mercury filled Temperatu
re gauges. For Analog medium thermocouples are used And for Digital medium Switc
hes are used which are basically mercury switches. FLOW MEASUREMENT Flow measure
ment does not signify much and is measured just for metering purposes and for mo
nitoring the processes ROTAMETERS:
P a g e | 68
A Rotameter is a device that measures the flow rate of liquid or gas in a closed
tube. It is occasionally misspelled as rotometer . It belongs to a class of me
ters called variable area meters, which measure flow rate by allowing the cross
sectional area the fluid travels through to vary, causing some measurable effect
. A rotameter consists of a tapered tube, typically made of glass, with a float
inside that is pushed up by flow and pulled down by gravity. At a higher flow ra
te more area (between the float and the tube) is needed to accommodate the flow,
so the float rises. Floats are made in many different shapes, with spheres and
spherical ellipses being the most
P a g e | 69
common. The float is shaped so that it rotates axially as the fluid passes. This
allows you to tell if the float is stuck since it will only rotate if it is not
. For Digital measurements Flap system is used. For Analog measurements we can u
se the following methods : Flowmeters Venurimeters / Orifice meters Turbines
Massflow meters ( oil level ) Magnetic Flowmeter ( water level )

Ultrasonic Flow meters

P a g e | 70
Selection of flow meter depends upon the purpose , accuracy and liquid to be mea
sured so different types of meters used. Turbine type are the simplest of all. T
hey work on the principle that on each rotation of the turbine a pulse is genera
ted and that pulse is counted to get the flow rate. VENTURIMETERS :
P a g e | 71

Referring to the diagram, using Bernoulli s equation in the special case of inco
mpressible fluids (such as the approximation of a water jet), the theoretical pr
essure drop at the constriction would be given by (ρ/2)(v22 - v12). And we know th
at ate of flow is given by: Flow = k √ (D.P) Whe e DP is Diffe ential P esu e o
the P essu e D op. CONTROL VALVES A valve is a device that egulates the flow of
substances (eithe gases, fluidized solids, slu ies, o liquids) by opening, c
losing, o pa tially obst ucting
P a g e | 72
various passageways. Valves are technically pipe fittings, but usually are discu
ssed separately. Valves are used in a variety of applications including industri
al, military, commercial, residential, transportation. Plumbing valves are the m
ost obvious in everyday life, but many more are used. Some valves are driven by
pressure only, they are mainly used for safety purposes in steam engines and dom
estic heating or cooking appliances. Others are used in a controlled way, like i
n Otto cycle engines driven by a camshaft, where they play a major role in engin
e cycle control.
P a g e | 73
Many valves are controlled manually with a handle attached to the valve stem. If
the handle is turned a quarter of a full turn (90°) between operating positions,
the valve is called a quarter-turn valve. Butterfly valves, ball valves, and plu
g valves are often quarter-turn valves. Valves can also be controlled by devices
called actuators attached to the stem. They can be electromechanical actuators
such as an electric motor or solenoid, pneumatic actuators which are controlled
by air pressure, or hydraulic actuators which are controlled by the pressure of
a liquid such as oil or water. So there are basically three types of valves that
are used in power industries besides the handle valves. They are :
P a g e | 74
Pneumatic Valves – they are air or gas controlled which is compressed to turn or m
ove them Hydraulic valves – they utilize oil in place of Air as oil has better com
pression Motorised valves – these valves are controlled by electric motors

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Co-ordination of house load to the generated power output.

Protection of individual process components against overstress (in a stable or u

CONTROL AND MONITORING MECHANISMS

Massflow meters ( oil level ) Magnetic Flowmeter ( water level )

INDUSTRIAL TRAINING REPORT BY DIGVIJAY SINGH Email Id- singh_digvijay89_yahoo.in

INDUSTRIAL TRAINING REPORT BY DIGVIJAY SINGH Email Id- singh_digvijay89_yahoo.in

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