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INDUSTRIAL TRAINING
AT
REPORT
Submitted by,
SOHAN RAM CHOUDHARY 08M268 MECHANICAL ENGINEERING
THE TRAINING:
I was given the opportunity to broaden my field of knowledge by having an exposure in such an industry. The industrial training commenced in 1 June, 2010 to 30 June, 2010. I was given the following machines to visit during my 4 weeks of training period: 1. Gas Turbine 2. Steam Turbine 3. Combustion Chamber 4. Cooling Tower
Gas Turbine GT Compressor Combustion Chambers Air filter type and Particle Size
05)
Bypass Stack
06) Waste Heat Recovery Boiler (WHRB) 07) WHRB Steam Parameters HP Steam LP Steam Steam Turbine
08)
09) 10)
Condenser Generator rated output Rated Terminal voltage Rated speed Type of cooling Black start facility Cooling Tower type Cooling water (Design flow) Range of cooling Dimensions
11) 12)
: 106 MW, 3 Stage Impulse Type : 17 Stages Axial Flow Compressor : Cannular type with 2 Igniters and 14 Combustor baskets : Self cleaning inlet air filter, for removing 5 micron particle size and above and Handling air flow 380 kg/sec. : Vertical circular 5.93 m. dia & 55 m. high : Double drum, non-firing, assisted Circulation Type heat recovery boiler : Press Flow Temperature (Kg/cm) (Ton/hr) (Deg. C.) 71.3 174 520 7.1 40 192 : 116 MW, impulse, tandem Compound, Double exhaust, condensing type, with HP Turbine 13 stage horizontal single flow LP Turbine 5 stage horizontal double flow : Two Pass Surface Condenser, each Having 9200 no. Stainless Steel Tubes : 134 MVA for GT & 145 MVA for ST : 11.5 KV with Blushless Excitation : 3000 RPM : Air-Cooled : 2.5 MW Diesel Generator Set : Two Natural Draft Cooling Tower (One for each module) : 24000 m/hr : 10 C : 106.3 meters height & Base diameter of 92 m. : 5 (one common standby)/11910 m/hr & Design parameters 22.4 MWC : 2 Clariflocculators each rated for 1500 m/hr : Two streams of 55 m/hr
BRAYTON CYCLE
Gas turbine plants operate on this cycle in which air is compressed (process 1-2, in P-V diagram of figure-1B). This compressed air is heated in the combustor by burning fuel, where plant of compressed air is used for combustion (process 2-3) and the flue gases produced are allowed to expand in the turbine (process 3-4), which is coupled with the generator. In modern gas turbines the temp. of the exhaust gases is in the range of 500 C to 550 C.
RANKINE CYCLE:
The conversion of heat energy to mechanical energy with the aid of steam is based on this thermodynamic cycle. In its simplest form the cycle works as follows: The initial stage of working fluid is water (point 3 of figure 2), which at a certain temperature is pressurized by a pump (process 3-4) and fed to the boiler In the boiler the pressurized water is heated at constant pressure (process 4-5-6-1) Superheated steam (generated at point-1) is expanded in the turbine (process1-2), which is coupled with generator. Modern steam power plants have steam temperature in the range of 500C to 550 C at the inlet of the turbine.
Compressors are of the dynamic type, in which each stage increases the fluid velocity, and then lets it diffuse to gain pressure. Combustion (2-3): The fluid is heated by internal combustion, in a continuous processtaking place at constant pressure. A steady supply of fuel mixes with air at high velocity from the compressor and burns as it flows through a flame zone. Combustion occurs in a very small volume, partly because it takes place at high pressure. Expansion (3-4): The working fluid at high pressure is then released to the turbine, which converts the fluid's energy into useful work as the temperature of the working fluid decreases. Part of this work is returned to the compressor. The remainder is used for the application intended: Generation of electricity, pumping, and turbojet propulsion.
2 Fuel C 1 Figure-1: Joule Brayton Cycle T 3 4 Exhaust
The use of a compressible gas such as air as working fluid permits the absorption and release of considerable amounts of energy. Such energy is basically the kinetic energy of its molecules, which is proportional to its temperature. Ideal gas turbine cycles are based on the Joule or Brayton cycles, i.e., compression and expansion at constant entropy, and heat addition and release at constant pressure. In an ideal cycle, efficiency varies with the temperature ratio of the working fluid in the compression process, which is related to its pressure ratio. The inlet temperature in the turbine section is generally limited by turbine technology, materials strength, corrosion and other considerations. The increment of temperature also depends on the initial
Figure 2: PV and TS Diagram of Joule Brayton Cycle.
temperature of the working fluid. Some effects must be considered which diminish efficiency in real operating cycles, such as inefficiency in compression and expansion, loss of pressure during heat addition and rejection, variation of working fluid specific heat with temperature, incomplete combustion, etc.
development process takes time, however, because each change of material may require years of laboratory and field tests to ensure its suitability in terms of creep
strength, yield limit, fatigue strength, oxidation resistance, corrosion resistance, thermal
The above figure shows how overall (net) efficiency of simple and combined-cycle power plants has improved since 1950. The efficiency of simple cycle gas turbine plants has doubled, and with the advent of combined-cycle plants, efficiency has tripled in the past fifty years. Turbine nozzles and buckets are cast from nickel super alloys and are coated under vacuum with special metals to resist the hot corrosion that occurs. The high temperatures encountered in the first stage of the turbine are of great importance, particularly if contaminants such as sodium, vanadium and potassium are present. Only a few parts per million of these contaminants can cause hot corrosion of uncoated components at the high firing temperature encountered. With proper coating of nozzles and buckets and treatment of fuels to minimize the contaminants, manufacturers claim the hot-gas-path components should last 30,000 to 40,000 hours of operation before
replacement, particularly the hot-gas-path parts, that give rise to the relatively high maintenance cost for gas turbines (typical O&M annual costs 5 percent of the capital cost).
The gas turbine is a common form of heat engine working with a series of processes consisting of compression of air taken from atmosphere, increase of working medium temperature by constant pressure ignition of fuel in combustion chamber, expansion of SI and IC engines in working medium and combustion, but it is like steam turbine in its aspect of the steady flow of the working medium. It was in 1939, Brown Beaver developed the first industrial duty gas turbine. The out put being 4000 KW with open cycle efficiency of 18%. The development in the science of aerodynamics and metallurgy significantly contributed to increased compression and expansion efficiency in the recent years. At Kawas, the GE-Alsthom make Gas Turbine (Model 9E) has an operating efficiency of 31% and 49% in open cycle and combined cycle mode respectively when natural gas is used as fuel. Today gas turbine unit sizes with output above 250 MW at ISO conditions have been designed and developed. Thus the advances in metallurgical technology have brought with a good competitive edge over conventional steam cycle power plant.
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The 9E model GEC-Alsthom package consists of Control compartment Accessory compartment Turbine compartment Inlet exhaust system Load package Generator excitation compartment CO2 fire protection unit Each station component is a factory assembled pretested assembly & is housed in all weather & acoustic proof enclosure. Advantages of gas turbine plant
Some of the advantages are quite obvious, such as fast operation, minimum site investment. Low installation cost owing to standardization, factory assembly and test. This makes the installation of the station easy and keeps the cost per installed kilowatt low because the package power station is quickly ready to be put in operation. Site implementation includes one simple and robust structure to get unit alignment. Transport: Package concept makes easier shipping, handling, because of its robustness. Low standby cost: fast start up and shut down reduce conventional stand by cost. The power requirements to keep the plant in standby condition are significantly lower than those for other types of prime movers. Maximum application flexibility: The package plant may be operated either in parallel with existing plants or as a completely isolated station. These units have been used, widely for base, peaking and even emergency service. The station can be equipped with remote control for starting, synchronizing & loading. Control reliability: the microcomputer based control, with an integrated temperature system (ITS) provides accurate control, quick protection and complete sequential start up & shut down & operation. Maintenance Cost is comparatively low.
Fuel nozzles Spark plugs Flame detectors BEARING ASSEMBLIES Quantity Lubrication No.1 bearing assembly (Located in inlet casing assembly) Journal Active thrust Inactive thrust No.2 bearing assembly (Located in the compressor discharge casing) No.3 bearing assembly (Located in the exhaust frame) STARTING SYSTEM Starting device Torque converter Fuel pump Gas stop ratio & control valve LUBRICATION SYSTEM Lubricant MOT capacityMain tube pump Emergency lube pump Auxiliary lube pump Heat exchanger (s) Type Quantity Filter (s) Type Quantity Cartridge type HYDRAULIC SUPPLY SYSTEM Main hydraulic supply pump Auxiliary hydraulic supply pump COOLING WATER SYSTEM Pumps Water cooling modules CONTROL SYSTEM SPEEDTRONIC MARK IV control system
11 One (1) per combustion chamber i.e. (one for gas & one for liquid) Two-(2) electrode type, spring-injected self-retracting. Four (4),ultra-violet type Three (3) Pressure lubrication Active and inactive thrust and journal, all contained in one assembly Elliptical Tilting pad, self-equalizing Tapered land Elliptical journal Journal, tilting pad
Electrical starting motor 1 MW drive Hydraulic with adjustor drive Accessory gear-driven, Continuous out put screw type pump Electro hydraulic servo-control Petroleum base 3,300 gallons (aprox.) i.e.12,540 litres (aprox.) Shaft driven. D.C. motor driven vertical submerged, centrifugal type (88QE) A.C. motor driven, vertical submerged, centrifugal (88QA) Oil heat to fresh water Two in parallel Full flow with transfer valve Two (Duplex) Five-micron filtration pleated paper. Accessory gear-driven, variable positive displacement, axial piston Driven by electric motor (88HQ), with accumulators- 2 nos.
Two water pumps located on lube oil tank inside the accessory compartment. 15 nos. fans and finned tube radiators
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Make Qty. installed Type Total heating surface Final temp of steam Overall length Design press
: COCKERILL mechanical industries :4 : dual drum, assisted circulation, vertical Unfired, dual pressure boiler : H.P=655504sq.m L.P=19938sq.m : H.P=520deg.C L.P=109deg.C : 15440mm : H.P=83bar L.P=7.6bar
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STEAM TURBINE:
Rankine Cycle :
Process 1-2 : Water from the condenser at low pressure is pumped into the boiler at high
pressure.this process is reversible adiabatic. Process 2-3: Water is converted into the steam at constant pressure by addition of heat in the boiler. Process 3-4 : Reversible adiabatic expansion of the steam in the steam turbine. Process 4-1 : Constant pressure heat rejection in the condenser to convert condensate into water. The steam leaving the boiler may be dry and saturated, wet or superheated. The corresponding T-S Diagram are 1-2-3-4-1; 1-2-3-4-1; 1-2-3-4-1.
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Steam Turbine
ST operates at 3000 rpm. The steam is provided to ST through the two WHRBS which are mounted at the exhaust of both the GT of each module. The single casing machine is equipped with two admissions to take HP & LP steam from HP & LP drums. The axial exhaust of ST is directly connected to the horizontally arranged 2 pass surface condenser.
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Losses in the system are made up by DM water from the DM water system. To achieve a defined quality of the water, and inhibitor dosing station is connected to CCW system.
COOLING TOWER:
Cooling Towers have one function:
Remove heat from the water discharged from the condenser so that the water can be discharged to the river or re circulated and reused.
Some power plants, usually located on lakes or rivers, use cooling towers as a method of cooling the circulating water (the third non-radioactive cycle) that has been heated in the condenser. During colder months and fish non-spawning periods, the discharge from the condenser may be directed to the river. Recirculation of the water back to the inlet to the condenser occurs during certain fish sensitive times of the year (e.g. spring, summer, and fall) so that only a limited amount of water from the plant condenser may be discharged to the lake or river. It is important to note that the heat transferred in a condenser may heat the circulating water as much as 40 degrees Fahrenheit (F). In some cases, power plants may have restrictions that prevent discharging water to the river at more than 90 degrees F. In other cases, they may have limits of no more than 5 degrees F difference between intake and discharge (averaged over a 24 hour period). When Cooling Towers are used, plant efficiency usually drops. One reason is that the Cooling Tower pumps (and fans, if used) consume a lot of power. Major Components Cooling Tower (Supply) Basin Water is supplied from the discharge of the Circulating Water System to a Distribution Basin, from which the Cooling Tower Pumps take suction. Cooling Tower Pumps These large pumps supply water at over 100,000 gallons per minute to one or more Cooling Towers. Each pump is usually over 15 feet deep. The motor assembly may be 8 to 10 feet high. The total electrical demand of all the Cooling Tower pumps may be as much as 5% of the electrical output of the station. Cooling Towers There are 2 types of towers - mechanical draft and natural draft Natural Draft Cooling Tower The green flow paths show how the warm water leaves the plant proper, is pumped to the natural draft cooling tower and is distributed. The cooled water, including makeup from the lake to account for evaporation losses to the atmosphere, is returned to the condenser.
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PLANT AT A GLANCE:
Open Cycle
CONCLUSION
After analyzing the NTPC 656.2 MW combined cycle power plant, we can describe that this power plant is very efficient one as compare to other power plant is very efficient. One as compare to other power plants in its series. Also we would like to add up that it is very compact in size, less pollute in nature, easily controlled and decent power plant that we had ever seen