Summer Training Presentation

Summer Training carried out at

NTPC Ltd., ANTA

Corporate Mentor: Presented by:
Pankaj Vashistha Nishant Pareek
Assistant Manager (2013UME1791)

Department of Mechanical Engineering

Malaviya National Institute of Technology, Jaipur
CONTENTS
I. NTPC Ltd. Overview
a) Plant Information and Capacity
b) ANTA GAS Power Station
II. Operation of a Combined Cycle Power Plant
III. Gas Turbine
IV. Steam Turbine
V. Waste Heat Recovery Boiler
NTPC Ltd. Overview
Plant information

• Established in 1975
• Became a Maharatna company in May 2010
• Ranked 400th in the 2016 ‘Forbes Global 2000’
• 44 NTPC stations -18 Coal based stations, 7 Gas based stations, 1 Hydro
based station, 9 Joint Ventures, 9 Renewable Energy Projects
• Diversified Fields - Consultancy, Power Trading, Training Of Power
Professionals, Rural Electrification, Ash Utilisation and Coal Mining
• Government of India’s holding - 75%
Growth in installed capacity: NTPC, NTPC
Group & All India
Strategies of NTPC
ANTA Gas Power Station
• First combined cycle power plant set up by NTPC
• Installed capacity of 419.33 MW
• Installed in 1989
• Gas Source – GAIL HBJ Pipeline-south basin gas field
• Water Source – kota right main canal
• Unit sizes - 3X88.71MW GTG+1X153.2MW STG
• Good efficiency
• Cost of power from ANTA = Rs. 1.97 per unit
UNIT COMMISSIONED: -

• 1. Unit I - 88.71 MW capacity GTG-1 January1989

• 2. Unit II - 88.71 MW capacity GTG-2 March 1989

• 3. Unit III- 88.71 MW capacity GTG-3 May1989

• 4. Unit IV- 153.2 MW capacity STG March1990

 ALLOCATION OF POWER TO STATES
STATES ALLOCATION IN MW PERCENTAGE
RAJASTHAN 83 19.81%
DELHI 44 10.5%
PUNJAB 49 11.69%
HARYANA 24 5.73%
HIMANCHAL 15 3.58%
J&K 29 6.92%
CHANDIGARH 05 1.19%
U.P 91.45 21.75%
UTTARANCHAL 15.88 3.79%
UNALLOCATED 63 15.04%
TOTAL 419.33 100%
SALIENT FEATURES OF NTPC ANTA
• 1. GAS TURBINE : 88.71MW, TYPE 13D-2, ABB MAKE, 5th STAGE
REACTION TURBINE
• 2. GT COMPRESSOR : 18th STAGE AXIAL FLOW, RECTION BLADING
• 3. COMBUSTION CHAMBER : SINGLE SILO TYPE, DUAL FUEL FIRED
BURNER
• 4. AIR INTAKE FILTER: SELF CLEANING, SYNTHATIC PAPER, TOTAL 945
FILTERS IN THREE TIERS.
• 5. BYPASS STACK : VERTICAL 25M.HIGH.
• 6. WASTE HEAT RECOVERY BOILER : DUAL PRESSURE, DOUBLEDRUM,
UNFIRED, FORCED CIRCULATION.

• 7. STEAM TURBINE :153.20MW, TANDEM COMPOUNDED,

DOUBLE EXHAUST, CONDENSING TYPE,
SINGLE FLOW HORIZONTAL 25 STAGE HP
TURBINE.

• 8. CONDENSOR : DOUBLE PASS SURFACE CONDENSOR

WITH STAINLESS STEEL TUBES,
COOLING 13988M3.

• 9. GENERATOR : 3 PHASES, TWO POLE, AIR COOLED

COMBINED CYCLE POWER PLANT LAYOUT.
There are four main parts of CCPP :

 Combine Cycle

 Gas Turbine

 Waste Heat Recovery Boiler

 Steam Turbine
 Overview of Combined Cycle
.
Gas turbine burns fuel.
• The gas turbine compresses air and mixes it with fuel that is heated to
a very high temperature. The hot air-fuel mixture moves through the
gas turbine blades, making them spin.

• The fast-spinning turbine drives a generator that converts a portion of

the spinning energy into electricity
Heat recovery system captures exhaust.
• A Heat Recovery Steam Generator (HRSG) captures exhaust heat from
the gas turbine that would otherwise escape through the exhaust
stack.
• The HRSG creates steam from the gas turbine exhaust heat and
delivers it to the steam turbine

Steam turbine delivers additional electricity.

• The steam turbine sends its energy to the generator drive shaft,
where it is converted into additional electricity.
 GAS TURBINE UNIT
• There are 3 Gas Turbine in NTPC ANTA each capacity of 88.71 MW
• TYPE 13D-2, ABB MAKE, 5th STAGE REACTION TURBINE
• Gas Turbine is a heat engine, working on the air standard Brayton cylcle.
The gas turbine compresses air and mixes it with fuel that is heated to a
very high temperature. The hot air-fuel mixture moves through the gas
turbine blades, making them spin
• The process include :

1. Compressor

2. Combustion

3. Expansion
 Working of gas Turbine
• The compressor sucks in air from the atmosphere through the filters
called air intake filters.
• . The compressed air at approx. 10.4 bar passes into the combustion
chamber
• The turbine and compressor are in common casing.
• The hot gases after combustion enter the gas turbine at about 10050C
(at base load).
• The higher pressure and temperature gas pass through the turbine
rotating it and generator, this produces the electrical power.
• The exhaust gas coming out of the GT is at about 5080C. This can be
utilized to produce steam in WHRB
Gas Turbine Components
• Air intake system

• Compressor

• Combustion chamber

• Turbine

• generator

• Naphtha fuel system

 Air intake system

• The air obtained from the environment contains

numerous pollutants and unwanted compounds which
may harm the machinery and reduce the efficiency of
the system
• AIR INTAKE FILTER Specifications :
• SELF CLEANING, SYNTHATIC PAPER,
• There are three horizontal floors in filter house each
floors carry 315 filters. TOTAL 945 FILTERS IN THREE
TIERS.
• All filters are made of synthetic and cellulose fibres,
using resign impregnated.
 Compressor
Gas Turbine COMPRESSOR Specification:
• 18th STAGE AXIAL FLOW, RECTION BLADING
• 18 rotor and 19 fixed rows blades
• Material used: Blade material: tensile ferric chrome steel.
Compressor casing: graphite cast iron.
• The compressor casing has three circular ducts at 4th, 7th and 10th row of fixed
blades.
• These ducts are closed to the outside by four bleed valves.
• . Bleed valves are kept open upto 2700 r.p.m so that certain amount of compressor
air can be blown off.
 Combustion chamber
• In combustion chamber, the air
compressed and supplied by compressor
is brought to the required process
temperature by combustion of liquid/gas
fuel.
• Specification: SINGLE SILO TYPE, DUAL
FUEL FIRED BURNER
• Material used: Combustion chamber is
welded steel plate fabricated.
Combustion chamber jacket,- low
alloy ferrite steel
 Turbine
• The gas turbine compresses air and mixes it with fuel that is heated to a very high
temperature. The hot air-fuel mixture moves through the gas turbine blades,
making them spin.
• Specifications: 88.71MW, TYPE 13D-2, ABB MAKE,
5th STAGE REACTION TURBINE
• turbine casing is made of heat resisting ferrite steel in order to with stand
• Thermal stresses. The blade carrier for turbine fixed blades is made of ferrite steel
alloy casting.
• Turbine blades are made ofcast nickel based alloy
• Due to high temperature of incoming gases, the first and second row of rotor and
fixed blading are air cooled with air from compressor discharge.
Cooling of turbine blades
• The cooling air is fed to the first & second row of fixed blades through
holes drilled in the blade carrier and to the first & second row of rotor
blades through hole drilled in shaft,
• cooling air passes along several holes made in blades and finally
blowing out through numbers of slits in the trailing/leading edge of
the blade.
• This method of cooling ensures that blades are thoroughly cooled,
thereby avoiding cracks induced by thermal stresses.
 Generator
Specifications : 3 PHASES, TWO POLE, AIR COOLED
• The generator and turbine are placed on common and plain concrete foundation,
with same centre line level for the turbine and generator rotor.
• The mechanical energy generated by turbine is converted to electrical energy by
the generator and appear in the stator winding in the form of current and
voltage.
• It lead the magnetic flux, and carries the field winding, the generator is self
excited. The power required for the excitation is taken from the generator term
finals and fed to the field winding through the excitation transformer and the
thyristor-controlled rectifier units.
 Naphtha fuel system
• Naphtha comes from naphtha station via the forwarding pumps at around 15bar.
• Naphtha then passes through duplex filter to the main fuel oil pump, which raises the press to
approx. 80 bar. There is release valve which opens when firing speed is reached (600rpm).
 WASTE HEAT RECOVERY BOILER
• Wagner-biro supplied boilers for anta combined cycle power plant
known as waste heat recovery boilers (WHRB), which are of non fired,
dual pressure, forced circulation type
• The boiler has two different water/steam cycles known as high
pressure system and low pressure system. Each system has its own
boiler drum and circulating pumps, and is feed by HP & LP feed water
pumps from a common feed water tank.
• The pressure and temperature of high pressure super heated steam is
64 bar and 4900C and that of LP 6 bar and2060C.
VARIOUS ACCESSORIES USED IN (WHRB) ARE:
• 1.SUPERHEATER- Super heater is used to raise the temperature of steam
above the saturation temperature by absorbing the heat from flue gases

• 2. EVAPORATOR- An evaporator is the component of a refrigeration system

and is used to extract heat from the chamber is to be kept at low
temperature
3. ECONOMIZER- The function of an
economizer in a steam generating unit is to
absorb heat from the flue gases and add this
as sensible heat to the feed water

4. AIR PREHEATER- An air preheater is used

to recover heat from flue gases. It is installed
between the chimney and economiser
5. DEAERATOR- It is used to remove air from water as air carries oxygen
which is corrosive in nature so to protect the various parts of boiler from
corrosion.

6. DESUPERHEATOR- It is used keep the temp. Of superheated steam

constant
WASTE HEAT RECOVERY BOILER
WHRB Working………
 Maintenance of boiler
• Cleanliness
• Proper air circulation
• Use boiler operating log sheets & maintenance records
• Ensure personnel properly trained
• Before start-up, ensure that the boiler is free of all potentially dangerous
situations
• Clear intakes and exhaust vents; check for deterioration and possible leaks
• Ensure a thorough inspection by a properly qualified inspector
• Establish a checklist for proper start up and shutdown of boilers
• Maintenance of boiler on frequent basis depending on the component part
 STEAM TURBINE UNIT
• Function of Steam turbine - Extracts thermal energy from
pressurized steam and converts it into rotary motion.
• Turbine classification:
i. Impulse Turbine
ii. Reaction Turbine
• Stationary blades - Potential energy of the steam  Kinetic
energy and direct the flow onto the rotating blades
• Rotating blades - Kinetic energy  Forces, caused by pressure
drop, which results in the rotation of the turbine shaft
There is one steam turbine in NTPC ANTA of capacity 153.2MW
Components of steam turbine
1. Turbine shaft
2. Turbine casing
3. Moving blades fixed on rotor
4. Fixed blades fixed on casing
5. Turbine bearings and couplings
6. Stop and Control Valves
7. Barring Gear
The Main Turbine (Tandem 3 cylinder turbine)
HP Turbine – 25 stages • H.P and L.P. turbine rotor - Rigidly
compounded
LP Turbine – 2*6 stages • L.P. and H.P rotor - Lens type semi
flexible coupling
 STEAM TURBINE SPECIFICATION
• MAKE : ABB , GERMANY
• RATED OUTPUT : 153.28 MW
• MAX. TERMINAL OUTPUT : 173.18 MW
• LIVE STEAM PRESSURE
• HP : 62.7 bar (abs.)
• LP : 5.5 bar (abs.)
• LIVE STEAM TEMPERATURE
• HP : 485 0C
• LP : 207 0C
• VACUUM : 0.1 bar(abs.)
• SPEED : 3000 RPM
 HP TURBINE
• NO. OF STAGES : 25
• TOTAL HP STEAM FLOW : 459 t/hr.
• HP MS PRESSURE : 61.75 bar
• HP MS TEMPERATURE : 485 0C
• HPT EXH. PRESSURE : 4.27 bar
• HPT EXH. TEMPERATURE : 181.8 0C

LP TURBINE
NO. OF STAGES : 2X6,double
flow
TOTAL LP STEAM FLOW : 117.3
t/hr.
LP MS PRESSURE : 4.5 bar
LP MS TEMPERATURE : 207 0C
LPT EXH. TEMPERATURE : 45.9 0C
Maintenance of steam turbine
Part Affected Wear out problem Comments, suitable condition
monitoring
Blading Erosion by solid particles Usually occurs gradually, worst at inlet
blading. Performance analysis detects.
Blading Parts breaking off Usually sudden. Vibration analysis
detects. (ANSYS Software)
Bearings Scoring damage to white metal Performance analysis, vibration analysis,
wear particles in oil
Rotors Rubbing, temporary unbalance, cracking, Vibration analysis, and off-line, some
misalignment NDT
Steam valve strainers, valves Deposits Likely to occur gradually, mostly in areas
spindles around 260°C. Performance analysis
detects.
Generator rotor, stator Insulation faults Electrical plant testing several
techniques
Condenser Air in leakage Tube fouling Performance analysis
Feedwater heaters Air in leakage, tube fouling by scale or oil Performance analysis
Valves- HP, IP bypass Leakage Performance analysis. Acoustic leakage
detection is also possible
References
I. NTPC Limited (n.d.). Company History. Retrieved from
http://www.ntpc.co.in/en/about-us/history
II. NTPC Limited (n.d.). Growth of NTPC. Retrieved from
http://www.ntpc.co.in/en/about-us/ntpc-overview
III. Bolaji and Emeka, R. 2014. Operation and Maintenance Schedule of a
Steam Turbine Plant in Lappeenranta, Masters Thesis, Saimaa University
of Applied Sciences. 99p
IV. http://www.instrumentationengineers.org/2013/06/working-principle-
of-impulse-turbines.html
V. http://energy.gov/fe/how-gas-turbine-power-plants-work
VI. http://www.ntpc.co.in/en/services-and-
initiatives/consultancy/services/operation-and-maintenance-o-and-m