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INDUSTRIAL TRAINING
AT

REPORT
Submitted by,
SOHAN RAM CHOUDHARY 08M268 MECHANICAL ENGINEERING

Introduction to NTPC Ltd.


NTPC, the largest power Company in India, was setup in 1975 to accelerate power development in the country. It is among the worlds largest and most efficient power generation companies. In Forbes list of Worlds 2000 Largest Companies for the year 2009, NTPC occupies 317th place. NTPC has installed capacity of 31,704 MW. It has 15 coal based power stations (24,825 MW), 7 gas based power stations (3,955 MW) and 5 power stations in Joint Ventures (2,864MW). The company has power generating facilities in all major regions of the country. It plans to be a 75,000 MW company by 2017. NTPC has gone beyond the thermal power generation. It has diversified into hydro power, coal mining, power equipment manufacturing, oil & gas exploration, power trading & distribution. NTPC is now in the entire power value chain and is poised to become an Integrated Power Major. NTPC's share on 31 Mar 2008 in the total installed capacity of the country was 19.1% and it contributed 28.50% of the total power generation of the country during 2007-08. NTPC has set new benchmarks for the power industry both in the area of power plant construction and operation. With its experience and expertise in the power sector, NTPC is extending consultancy services to various organizations in the power business. It provides consultancy in the area of power plant constructions and power generation to companies in India and abroad. Recognizing its excellent performance and vast potential, Government of the India has identified NTPC as one of the jewels of Public Sector 'Navratnas'- a potential global giant. Inspired by its glorious past and vibrant present, NTPC is well on its way to realize its vision of being "A world class integrated power major, powering India's growth, with increasing global presence".

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

FLOW CHART OF NTPC KAWAS PLANT:

SALIENT FEATURES OF PROJECT


01)

02) 03) 04)

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)

13) 14) 15)

Cooling water pumps/ Pre-treatment Plant DM Water Plant

: 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

COMBINED CYCLE POWER PLANT:


Combine cycle power plant integrates two power conversion cycle-Brayton cycle (Gas turbine) and Rankine cycle (Steam turbine) with the principal objective of increasing overall plant efficiency.

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.

COMBINING TWO CYCLES TO IMPROVE EFFICIENCY


We have seen in the above two cycles that exhaust is at temperature of 500-550 C and in Rankine cycle heat is required to generate steam at the temperature of 500-550 C. Therefore gas turbine exhaust heat can be recovered using a waste heat recovery boiler to run a steam turbine on Rankine cycle. If efficiency of gas turbine cycle (when natural gas is used as fuel) is 31% and the efficiency of Rankine cycle is 35%, then over all efficiency comes to 49%. Conventional fossil fuel fired boiler of the steam power plant is replaced with a heat recovery steam generator (HRSG). Exhaust gas from the gas turbine is led to the HRSG where heat in exhaust gas is utilized to produce steam at desired parameters as required by the steam turbine.

Evolution of gas turbines and combined cycle plants Early History


Gas Turbines or Combustion turbines (an expression which has become popular in past few years) were first developed in the late 18th century. Patents for modern versions of combustion turbines were awarded in late nineteenth century to Franze Stolze and Charles Curtis, however all early versions of gas turbines were impractical because the power necessary to drive compressors outweighed the power generated by turbine. This is because of the fact that the turbine inlet temperature (TIT) required to deliver positive output and a certain minimum acceptable efficiency was above the allowable temperatures that could be faced by materials available in those days. For example in 1904 two French engineers, Armengaud and Lemale built a unit, which did little more than turn itself over. The reason maximum temperature that could be used was about 500 degree C and the compressor efficiency was abysmally low at 60 %. 3.1.2Gas turbine performance effect of tit and compression ratio A Gas Turbine in its simplest form works on Joule Brayton Cycle, which consists of following: Compression (1-2): A rotating compressor acts as a fan to drive the working fluid into the heating system. The fluid is pressurized adiabatically, thus its temperature increases.

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.

Gas Turbine Design Advancements:


In gas turbine design the firing temperature, compression ratio, mass flow, and centrifugal stresses are the factors limiting both unit size and efficiency. For example, each 55C (100F) increase in firing temperature gives a 10 - 13 percent output increase and a 2 - 4 percent efficiency increase. The most critical areas in the gas turbine determining the engine efficiency and life are the hot gas path, i.e., the combustion chambers and the turbine first stage stationary nozzles and rotating buckets. The

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

Increase in Efficiency over the years.

cycling effects, etc.

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).

GAS TURBINE PLANT:


Introduction:

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.

Kawas Gas Turbine Plant:


The modern gas turbine plants are commonly available in package form with few functional sub assemblies.

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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.

GAS TURBINE EQUIPMENT DATA SUMMARY


COMPRESSOR SECTION Number of compressor stages Compressor type Casing split Inlet guide vanes TURBINE SECTION Number of turbine stages Casing splits Nozzles COMBUSTION SECTION Type Seventeen (17) Axial flow, heavy duty Horizontal flange Modulated Three (3) Horizontal Fixed area Fourteen (14) multiple combustors, reverse flow design

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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Gas Fuel System


The gas fuel system is designed to deliver gas fuel to the turbine combustion chamber at the proper pressure and flow rates to meet all of the starting, acceleration and loading requirements of gas turbine operation. A schematic diagram of the gas fuel system is given in figure. The major components of a gas fuel system are the gas stop/ratio and gas control valves located on the accessory base. Associated with the two gas valves are the necessary inlet piping strainer, fuel vent valve, control servo valves, pressure gauges and the distribution piping to the 14 combustion fuel nozzles. The fuel gas stop ratio valve and the gas control valve, two independent valves, are located inside the gas fuel panel, of the accessory base. The gas fuel flows through the gas stoop ratio valve and then into the gas control valve on its way to the gas manifold and individual combustion chambers. The position of each valve is servo controlled by electrical signals from the gas turbine SPEEDTRONIC control system. Both the gas stop ratio valve and gas control valve are actuated by single acting, hydraulic cylinders The following major components comprise the gas fuel system: Strainer Fuel gas supply pressure alarm switch Gas stop ratio valve VSR Gas control valve VGC Stop ratio LVDTS 96GC-1, 2 Stop ratio valve-control servo valve 90SR Gas control valve- control servo valve 65 GC Gas fuel dump valves VH5 and VH12 Gas fuel vent solenoid valve 20 VG-1 and 2 Pressure gauges Lines to the 14 combustion chambers

Liquid Fuel System:


The liquid fuel system pumps and distributes fuel as supplied from the off base forwarding system, to the fourteen fuel nozzles of the combustion system. The fuel system filters the fuel and device the fuel flow in to 14 equal parts for distribution to the combustion chamber at the required pressure and flow rates. Controlling the position of the fuel pump bypass valve VC3 regulates the amount of fuel input to the turbine combustion system by varying the amount of bypassed fuel. The fuel system shown in the schematic diagram is comprised of the following major components plus several other control devices, switches and gauge. Temporary fuel oil strainer SFI Fuel oil stop valve VSI. Liquid fuel pumps PFI. Fuel pump discharge relief valve VR-4 Fuel bypass valve VC-3 High-pressure fuel strainer Fuel line check valve Fuel nozzle assemblies False start drain valve VA17-1 andVA17-2 (in bottom of combustion wrapper and exhaust frame) Control device also associated with the fuel system include the liquid fuel pressure switches 63 FL-2, Servo valve 65 FP that controls the fuel bypass valve, fuel clutch solenoid 20 CF, and permissive limit switches 33 FL-1 an 2 and trip relay valve VH4 in the fuel oil stop trip control circuit.

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Atomizing Air System


Atomizing air system provides sufficient pressure in the air atomizing chamber of the fuel nozzle body to maintain the ratio of atomizing air pressure to compressor discharge pressure at approximately 1.2 or greater over the full operating range of the turbine. Since the output of the main atomizing air compressor, driven by the accessory gear, is low at turbine firing speed, during starting, atomizing air compressor provides a similar pressure ratio during the firing and warm up period of the starting cycle and during a portion of the accelerating cycle. Continuous blow down to atmosphere is also provided to clear the main gas turbine compressor of accumulated dirt. Major system components include: the main atomizing air compressor, starting air compressor, atomizing air heat exchanger and an air filter.

WASTE HEAT RECOVERY BOILER: (WHRB)


The exhaust hot gases of the GT come to the Waste Heat Recovery Boiler (WHRB) if we do not bypass them through bypass stack. The WHRB produces superheated steam at Low & High pressures. The steam generator comprises of an economizer, an evaporator with drum and a super heater section for both LP & HP systems. Boiler used here in KGPP is waste heat recovery type which is generally denoted WHRB. Waste heat recovery boiler general details: The WHRB includes the following: 1. Water heater 2. L.P economizer 3. H.P economizer 4. L.P evaporator 5. H.P evaporator 6. L.P super heater 7. Two H.P super heater 8. L.P & H.P drum 9. L.P & H.P circulating pumps 10. Diverter damper 11. Weather protection damper 12. Bypass stack 13. Chimney

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.

Steam Bypass System


To increase operation and start-up flexibility of the plant, a steam bypass system is integrated, which automatically goes into operation, if any of the following operation cases occur: a. ST start-up or shutdown, b. Turbine trip The steam bypass system is designed to handle the whole steam production at full pressure under all ambient conditions. It consists of an isolating and a steam pressure reducing valves with integrated water injection and the associated measurement, control and protective devices. Injection water for desuperheating of the steam is taken from the main condensate line.

Cooling Water System


A natural draught wet cooling tower system transposes the waste heat of the water steam cycle to the atmosphere. Two 100% main cooling water pumps supply the cold water from the cold-water basin to the main condensers and the intercoolers of the CCW system. The condenser tubes in clean conditions. Losses in the system are made up by clarified raw water. The cooling water quality is controlled by the cooling water sampling water sampling and dosing station, where chemicals can be dosed. Closed Cooling Water System A separate closed cooling water system for each unit ensures the cooling of the lube oil system, the HP feed water pumps, the LP boiler preheated circulating pumps, the generator air coolers, the sampling system, etc. The heat is dissipated to the main cooling water system via 100% capacity water-towater heat exchanger.

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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:

GAS TURBINE DESIGN EFFICIENCY


Heat Rate (Kcal/Kwh) Efficiency (%)

Open Cycle

Gas Liquid fuel


Combined Cycle

2695 2730 1741 1776

31.8 31.4 49.23 48.26

Gas Liquid fuel

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

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