OVERVIEW OF CAPTIVE POWER PLANT

• Total generating capacity of captive power

plant is 228.5 MW
• Steam turbine generators 3X25 MW
• Gas turbine generator 5X30.7 MW
• The gas turbine is simple cycle, single
shaft drives a synchronous generator,
which is supplied, erected and
commissioned by BHEL
There is 132 KV, grid (HSEB) as stand by
source. The generator output fed to the 11
KV generation bus through unit ratio
Transformer and Generation bus is coupled
with grid, through two startup transformers.
Power is supplied from grid for initial start of
power plants and for abnormal conditions.
Two lines are taken from Panipat Thermal
Power Station. The Line #1 is directly
terminated to IOCL switchyard. But line #2 is
terminated to switchyard after line IN and line
Out at MUNAK substation of HSEB.
Two 132/11.5 KV grid transformers #1 and #2
of 12.5/16 MVA are installed and connected
to 11 KV generation bus of captive power
plant. In normal operations, only one
incoming line and one startup transformer
will be in service, to meet any shortfall of
power in refinery. For 132 KV switching
operation, 245 KV grade SF6 circuit breakers
have been installed. PLCC (Power Line
Carrier communication) has been
incorporated for communication with HSEB
and protection of 132 KV transmission lines.
A contact demand has been executed with
HSEB for import of 10 MVA power load.
Switchyard is the connecting link between the
generating plant and the transmission system. 132
KV Switchyard of Panipat Refinery Captive Power
plant facilitates the drawl of the start up power from
the HSEB grid or in case of emergency to meet the
requirement of refinery load through start
Transformers and switchyard equipments. High
voltage transmission lines are connected to132 KV
Bus bars through the set of switching equipment.
Bus bars are mounted on high gantry type structure
and equipments are mounted on Lattice structure.
The operation of this system is controlled from
common control room through a network of cables,
which are laid in cable trench.
 The 132KV switchyard of Panipat Refinery
has been constructed and designed by
NTPC. It consists of 5 bays with double bus
bar system. They are;
• Bay-1 for 132 KV start up transformer-1.
• Bay-2 for 132 KV line - 1 from Panipat.
• Bay-3 for 132 KV line - 2 from Munak.
• Bay-4 for 132 KV bus coupler
• Bay-5 for 132 KV start up Transformer-2
The two independent 132 KV incoming line to
switchyard comes from two 132/11.5 KV grid
transformer also called as startup transformer of
12.5 MVA are installed to step down 132 KV to 11
KV. These start-up transformers are connected to
11 KV generation bus of CPP. For 132 KV
switchyard operations, 245 KV grade SF6 circuit
breakers have been installed. PLCC (Power line
carrier communication) has been incorporated for
communication with HVPN and for protection of
132 KV transmission line.
 CPP CYCLES
Gas Turbine (Brayton) Cycle
 GT EXHAUST

COMB

FUEL
COMP TURB LOAD

INLET EFFICIENCY: 28 to 34%

AIR
GT Open cycle efficiency < Wise/Qf*CVf

Where
• Wise = Isentropic work done in gas turbine -
Isentropic work consumed in compressor
• Qf = Mass flow of the fuel
• CVf = Calorific Value of the fuel
 Simple cycle process equipments are
placed on the same axis of rotation
• Starting device,
• Fuel pump,
• Atomizing air compressor,
• Lube oil pump,
• Main compressor,
• Gas turbine,
• Electricity generator
• Exciter
Out put = WGT - WC + heat recovered in HRSG
Combined Cycle
Out put = WGT - WC + WST
 AXIAL COMPRESSOR
The compressor consists of 17 stages operating in
series each stage consists of rotating & stationary
row of blades (diffusers) converting the kinetic
energy to pressure energy
• The compressed air is used in Gas Turbine for;
• Combustion of fuel in combustion chamber
• Cooling of various turbine parts
• Sealing of oil in the bearings
• Pulsation control during start up and shutdown
• Purging of air filters
 Compressor Component
• Inlet Guide Vanes (IGV)
• Stator of the Compressor
1. Inlet Casing; located at the forward end of the compressor. It uniformly distribute air in
to the compressor and it supports the rotor bearing no-1
2. Compressor Casing; contains 1st to 10th stage of the compressor.
3. Discharge Casing; contains last seven stages i.e. from 11th to 17th stage of
compressor. It provides; Inner support to 1st stage nozzles of the turbine, Couples the stator
of turbine and compressor and Supports the outer combustion chambers.

• Rotor
1. The 17 stage axial flow rotor increases pressure and velocity
2. Most of the velocity is converted into pressure head by
diffuser vanes fitted into the casing.
3. Number of moving blade stages = stationary vane diffuser
stages
Compressor Rotor
 Inlet Air & Filter System
• Single stage self cleaning - cylindrical filter cartridges
attached to the bottom of a horizontal module plate
attached to the bottom of a horizontal module plate
• Skirts are suspended around the exposed sides of the
cartridges to protect them from damage
• Sequentially cleaned during normal turbine operation by
reverse flow pulses of pressurized air
• The pulse of air timer/ sequencer maintains operating air
flow resistance from 5.0 to 8.0 mmwcl gauge (i.e. pulse
air flow starts at dp > 8 and stops at dp < 5)
• Pulse frequency for cleaning is 3-6 pulses per minute
• Air temperature < 80 deg C to prevent damage to the
valve diaphragms.
 Cooling & Sealing Air System
• Seal Air for Turbine Bearings - fifth stage and maintain
lubricating fluid within the bearing housing that otherwise
might seep past the mechanical seal
• Compressor pulsation protection during startup /
shutdown - eleventh stage: discharged to atmosphere
through turbine exhaust air operated extraction valves
• Provide an operating air supply for the air operated
valves
• Cool the internal parts, outer shell and exhaust frame of
the turbine
• Provide pulse air to the self-cleaning inlet air filters
• Act as primary source of air used as atomizing air
 Combustion System
The Reverse flow type. High-pressure air path
reverses in the transition pieces and moves to
the annular spaces of all the ten combustion
chambers. The airflow through the combustion
chamber has three functions:
• To oxidize the fuel.
• To cool the metal parts.
• To dilute hot gas to the desired turbine inlet
temperature.
 COMBUSTION SYSTEM
COMPONENTS & FUNCTIONS
1. Fuel Nozzles
• Disperses and mixes the fuel with proper
amount of combustion air
• Each combustion chamber has one nozzle and
each nozzle has four inlets for Natural Gas,
Liquid Fuel, Purge Air, and Atomizing air.
• The liquid fuel is atomized by means of
atomizing air.
• The swirl tip in the nozzle imparts a swirl in the
combustion air for complete combustion and
resulting in the smoke free operation of the unit.
Fuel Nozzle
2. Spark Plug
• Combustion is initiated by the spark plugs
provided in the two combustion chambers and
fire in the remaining chambers is ignited through
crossfire tubes
• The spark plug operates at 11 kV supplied by
ignition transformer
• Spark plugs are installed in combustion chamber
no-1 and 10 only, which are spring injected and
pressure retracted type
• As the rotor speed increases, chamber pressure
causes the spark plugs to retract and the
electrodes are removed from combustion zone.
As the rotor speed increases, chambers are
ignited through crossfire tubes only
 3. Cross Fire Tubes
Cross fire tubes (form a passage)
propagate the flame from one combustion
chamber to the other, after the initiation of
fire by spark plug
 4. Combustion Chamber
In the combustion chamber, hot gases
from the reaction zone passes to the
dilution zone where additional amount of
air is mixed to bring the temperature of hot
gases to the desired level. A film of main
compressor discharge air shields the liner
wall from the hot combustion gases
 Retractable
Spark plug
Dilution zone
Reaction Cooling air
zone Mixing zone Combustion
liners

Transition piece

To Turbine
Fuel nozzle
nozzle

Air from
compressor

Cross fire
tubes
 5. Ultra Violet Flame Detectors
During the starting sequence, it is essential that
indication of the presence or absence of flame in the
combustion chambers be transmitted to the mark-V.
The four nos. of flame detectors are provided in
combustion chamber 3, 4, 7 & 8 to meet the
purpose.

6. Transition Pieces
It directs the hot gases from the liners to the turbine
nozzle
 Atomizing & Purge Air System
ATOMISING AIR
• Atomizing air is required to break the fuel jet to increase
combustion efficiency
• Atomizing air pr / compressor discharge pressure > 1.2
• Main atomizing air compressor (driven by accessory gear box)
• Starting (booster) compressor driven by starting device (Diesel
engine)
• The atomizing air manifold distributes air to all the ten individual
fuel nozzles
• Atomizing air is not required for gaseous fuel
PURGE AIR SYSTEM
• The purge air keeps oil fuel nozzles clean and ready for
operation & also supplied from the atomizing air system.
 Liquid Fuel System
• The liquid fuel system provides fuel oil to the gas
turbine in response to the speed and load demands
and within temperature limitations of the turbine.
The fuel pump is a positive displacement, high
pressure discharge flow, modulated by the servo
controlled by pass valve. The valve subtracts
excess fuel flow to the combustion system as
determined by control system. The modulated fuel
flow is then filtered by a high pressure filter and
divided into ten equal parts by the flow divider. The
purpose of the flow divider is to equally divide the
fuel oil to each of the fuel nozzles of the turbine.
• The fuel stop valve in the liquid fuel oil system is
used to shut off the supply of fuel during normal
and emergency shutdown
 STARTING SYSTEM (DIESEL ENGINE)

Diesel engine develops 630 HP/470 kW at 2300 RPM.

Gas turbine is first to be cranked up to a certain
minimum speed i.e. 20% of full speed no load (FSNL)
which is 5133 RPM. After attaining this speed, the firing
starts but cranking is continued until the turbine reaches
the self sustaining speed i.e. 60% of FSNL. Hence a
starting device (D.E.) is required to supply a high torque
at the time of starting to drive the turbine up to the firing
speed and then assisting the fired turbine to reach the
self sustaining speed. The diesel engine also drives the
startup compressor till the main compressor comes into
service.
Steam type Source Use
Very high pressure VHP Boiler Turbine input
(VHP) - P-100Kg/cm2 HP/MP PRDS
Temp-500 deg. C Aux. PRDS

High Pressure (HP) HPPRDS Process Unit

P-40Kg/cm2 New 6 HP boilers (HRSG
Temp-400 deg. C 2-5 , 2 UB)
Medium Pressure (MP) Extraction-1 of turbine Process Unit
P-16.5kg/cm2 MPPRDS HP heater
Temp-350 deg. C HRSG-1 Aux. PRDS
Low Pressure (LP) Extraction-2 of turbine Deaerator
P-5Kg/cm2 LPPRDS
Temp-270 deg. C
Auxiliary (Aux.) Aux. PRDS Vacuum creation in
P-11ata MP steam condenser - Turbine
Temp -300 deg. C end gland sealing
 HEAT RECOVERY STEAM GENERATORS
• Heat recovery steam generator is a horizontal, natural
circulation, single drum single pressure, duct fired, water
tube boiler. Its heat source is GT exhaust plus
supplementary fuel oil. In HRSG, feed water continuously
circulate in it different parts and finally drawn out as super
heated steam.
• This process of conversion from water to super heated
steam by addition of Sensible heat of water in economizer,
Latent heat in evaporator (through large size down comers)
& Sensible heat of steam (superheat) in super heater
• The saturated steam is separated by the centrifugal
separators and scrubbers placed inside the drum.
• For controlling the final super heated steam temperature at
the rated value over the control rang of boiler, de-super
heater is mounted in between the super heater
 Parts and Functions of HRSG
1. Screen evaporator
Screen evaporator is the heat transfer section
located immediately after the duct burner. The
high temperature gases leaving duct burner
first enter the screen evaporator before
entering the superheater. Screen evaporator is
constructed of modules consists of two rows of
plain tubes welded to top and bottom headers
screen module is connected to drum by means
of riser pipes at the top and common feeder by
means of individual feeders at the bottom.
2. Evaporator
• Evaporator is the heat transfer section, arranged
next to super heater in the direction of gas flow the
evaporator along with screen modules constitute
the circulation system.
• The heated feed water from economizer enters the
steam drum, the boiler water from the drum flows
to the common feeder through down comer and is
distributed to the bottom header of the evaporator
modules through the individual feeders, steam
water mixture generated in the evaporator tubes.
Due to the heat transfer from flue gas to feedwater,
partial evaporation takes place, which cause
density difference and circulation back to the drum
through the riser tubes.
3. Super Heater
• Super heater is a heat transfer section arranged
next to screen evaporator in the direction of
gas flow. Super heater is constructed of modules
consists of rows of plane/spiral finned tubes
welded to top and bottom headers.
• Super heater is designed for single pass flow
on both gas side and steam side, Super heater
has two stages with inter stage super
desuperheater. The super heater modules are
equipped with drains for a fully drainable
design; the super heater outlet is equipped with
a vent for startup
4.Economizer
Economizer is the heat transfer section
arranged next to the evaporator,
economizer constructed of modules
consisting of rows of spiral-finned tubes
welded to top and bottom headers.
Economizer is designed for single pass
flow on the gas side and multi-pass flow
on waterside. Economizer modules are
equipped with high point 1’’ vent and low
point 1’’ drain for fully drainable design.
5.De Super Heater
• De super heater serves the purpose of
controlling the temperature of super heated
steam, which is achieved by spraying water by
tapped from feed water line through a spray tube
in to steam. The De super heater positioned
between SHI & SHII.
• Assembly consists of an outer shell, in which the
spray tube is positioned with the Help of an outer
nozzle. A liner is placed inside the shell and is
held in position concentrically by means of
positioning screws placed at three locations
along the shell length.
6.Make Up Water Heater
Make up water heater is the final heat
transfer section arranged in the direction
of gas flow. MUH is constructed of
modules consists of rows of spiral
finned tubes welded to the top and
bottom headers MUH designed for
single pass flow on gas side and multi-
pass flow on the water side.
7. Expansion joint
Two expansion joints are provided, one at
HRSG inlet and seconds at chimney inlet.
Expansion joints are provided to absorb
axial and lateral movements, including
continual vibration.
 Supplementary Firing System
• Storage Tanks: (2 HFO + 1 LDO) receive oil from
the bulk storage area of refinery.
• Pumps & Valves: Transfer/pressure pumps, trip
valves, flow control valves (30&100%), header pr
regulating valves and nozzle valves
• Oil Guns: 16 on 4 firing floors (2L+2R) axial fired
oil burner & duct burner
• Augmenting air: Required for low oxygen content
in turbine exhaust gas and admitted at the burner
throat.
• Atomisation fluid: MP steam for HFO & air for
LDO
 Boiler Feed Water System
• DM Plant - units for heat recovery through
booster pumps - deaerator.
• The DM water is having pH 8.5 to 9.0,
Conductivity 10 micro mho/cm (max) and silica <
0.001 PPM.
• Tri sodium phosphate is dosed tin drum reduce
residual hardness, scale forming salt and, non-
adhering sludge. The phosphate also maintains
pH of boiler drum water.
• CBD maintains the silica concentration within
limit
 Deaerating Heater & Feed Storage Tank

• Removes O2 & CO2 dissolved in water

• Store water for supplying to boiler feed
pumps.
• Provide NPSH to boiler feed pumps.
• The pump discharge at pressure 54
kg/sqcmg and temp 145 deg C through
economiser it enters the boiler drum.
Water/Steam Circulation in HRSG
FUEL FIRED STEAM GENERATORS
Boiler technical specifications
Max steaming cap. - 160 T/hr
SH Steam Pressure - 104
Kg/sqcm
SH Stem Temp. - 510 deg
C
Feed Water Temp at ECO inlet - 200 deg C
Excess Air - 20 % (oil) & 22.40 % (Gas)
Efficiency at 100 % MCR -
Steam Drum and Internals
Furnace
• Superheater: The boiler is provided with two
stages of super heaters i.e. Primary and
Secondary super heaters Retractable soot
blowers are provided between the primary and
secondary super heaters for cleaning.
• Desuperheater: Desuperheater is provided on
the connecting pipe between the primary and
secondary super heaters to control the final
steam temperature.
• Economizer: Economizer, a boiler accessory, is
used to recover flue gas heat and increase the
temperature of feed water before entering the
boiler.
 Blow Down Vessel
It is located at the boiler front at ground
floor & accommodate the following lines:
• CBD
• Super heater header drains
• ECO Inlet and outlet Header drains
• Soot Blower drain
• Bottom drain
• EBD
• SCAPH drain
• Rotary Air Preheater
The Rotary Air pre heater absorb waste heat
from the flue gas and transfers this heat to
incoming cold air by means of continuously
rotating heat transfer elements of specially
formed metal sheets.
• Steam Coil Air Pre Heater (SCAPH)
Steam coiled air pre heater is a heat transfer
equipment in which heat transfer takes place
between the two media namely steam and
air through the walls and fins of the finned
tubes
STEAM
TURBINE
CYCLE
STEAM TURBINE CYCLE
Turbine Extraction Overview
 GENERATOR
Eight electricity generators (5 GT + 3 ST driven) each
has following specifications;
• Active Power = 25 MW
• Apparent Power = 31.25 MVA
• Voltage = 11000 Volts
• Current = 1640 Amps
• P. F. = 0.8 lag
• Speed = 3000 RPM
• Frequency = 50 Hz
• Connection of Stator Winding = Y
• Unbalance Loading = 10 % Continuous
• Field Current for Rated Output = 633 Amps
• No Load Field Current = 226 Amps
• Generator Type = TART 750-24 P
• No. of Turbo generator Sets = 3
 Stator
• STATOR FRAME
It is of welded construction & supports the laminated
core, winding & both air duct pipes.
• STATOR CORE
It is made from insulated electrical sheet steel
laminations having high silicon content. The stator
frame is kept vertical while the core is stacked with
lamination segments in individual layers.
• STATOR WINDING
The stator winding is a fractional pitch two-layer type,
consisting of individual bars. The bars are located in
slots of rectangular cross section, which are uniformly
distributed on the circumference of the stator core.
 Rotor
• ROTOR SHAFT
The rotor shaft is a single piece solid forging manufactured
from a vacuum casting. Approximately 60 % of the rotor
body circumference are with longitudinal slots, which hold
the field winding.
• ROTOR WINDING
The field winding consists of several series connected coils
inserted into the longitudinal slots of the rotor body. The
coils are so wound that two poles are obtained. The field
connections provide the electrical connection between the
rotor winding & the exciter.
• BEARINGS
Generator rotor is supported in two journal bearings. The
exciter end bearing is insulated from foundation & oil piping
to prevent flow of shaft currents .The temperature of each
bearing The is monitored with one double element RTD.
 Excitation System
The generator & exciter rotors are supported on
total three bearings. The excitation system has a
revolving field with permanent magnet poles. The
three-phase ac output of this exciter is fed to the
field of the main exciter via a stationary regulator &
rectifier unit. Three-phase ac induced in the rotor
of the main exciter is rectified by the rotating
Rectifier Bridge & supplied to the field winding of
the generator rotor through the dc lead in the rotor
shaft. A common shaft carries the rectifier wheels,
the rotor of the main exciter & PMG rotor. The
shaft is rigidly coupled to the generator rotor.
 Excitation System Specifications
THREE PHASE PILOT EXCITER
• Output = 8 KVA
• Voltage = 220 Volts
• Current = 26 Amps
• Frequency = 150 Hz
• Speed = 3000 RPM
THREE PHASE MAIN EXCITER
• Output = 120 kW
• Voltage = 172 Volts
• Current = 696 Amps
• Speed = 3000
EXCITATION SYSTEM
BRUSHLESS EXCITOR ROTOR
 RECTIFIER WHEELS
• The silicon diode is the main component of the rectifier
wheels, which are arranged in a three-phase bridge
circuit. With each diode, a fuse is provided which serves
to cut off the diode from the circuit if it fails.
• For suppression of the momentary voltage peaks arising
from commutation, R-C blocks are provided in each
bridge in parallel with each set of diodes. The rings,
which form the positive & negative side of the bridge, are
insulated from the rectifier wheel which in turn is shrunk
on the shaft. The three phase connections between
armature & diodes are obtained via copper conductors
arranged on the shaft circumference between the
rectifier wheels & the main exciter armature.
 AUTOMATIC VOLTAGE REGULATOR
1. The voltage regulator is intended for the excitation and control
of generators equipped with alternator exciters employing
rotating uncontrolled rectifiers. The main parts of the regulator
equipment are two closed-loop control systems including a
separate gate control set and thyristor set each, field discharge
circuit, an open loop control system for exchanging signal
between the regulator equipment and the control room, and the
power supply circuits.
2. The active and reactive power ranges of the generator require a
wide excitation setting range. The voltage regulator in the
restricted sense, i.e. the control amplifiers for the generator
voltage controls via the gate control set the thyristors so as they
provide quick correction of the generator voltage on changing
generator load. For this purpose the gate control set changes
the firing angle of the thyristors as a function of the output
voltage of the voltage regulator.
 AUTOMATIC VOLTAGE REGULATOR
3. The main quantities acting on the input of the voltage regulator
are the set point and the actual value of the generator voltage.
The set point is divided into a basic set point (e.g. 90% rated
voltage) and an additional value (e.g. 0 to 20%) which can be
adjusted from the control room. In this case the setting range
is 90 to 110%. With operation at the respective limits of the
capability curve, further, influencing variable are supplied by
the under and over excitation limiters. To partly compensate
the voltage drop at the unit transformer, a signal proportional to
the reactive current can be added to the input, the controlled
voltage level then rising together with the reactive current
(overexcited) thereby increasing the generator degree of
activity in compensating system voltage functions. Further,
signals can be added if necessary via free inputs.
4. The use of the gate control set to introduce a field discharge
command. The signal, with priority over other influences,
drives the thyristor set to the maximum negative output voltage
(inverter operation).
 GAS TURBINE
The turbine has only three stages. Each
stage of the turbine consisted of a
stationary row of nozzles where the
velocity of high-energy gases is increased
and directed towards a rotating row of
buckets attached to the turbine shaft. The
high velocity gases push against the
buckets converting its kinetic energy into
the shaft power.
 GAS TURBINE PARTS
1. Turbine Stator
Turbine shell and exhaust frame comprises the
major portion of the turbine stator structure. The
turbine shell controls the axial and radial
positions of the shrouds and nozzles i.e. it
controls turbine clearances and relative position
of the nozzles to the turbine buckets. This
position is very critical for the GT performance.
2. Turbine Rotor
• It consists of DISTANCE PIECE, 1st STAGE
WHEEL & 1st & 2nd STAGE SPACER, 2nd STAGE
WHEEL AND AFT WHEEL SHAFT.
• The forward end of the first stage wheel is coupled
to the compressor rotor by the bolted flange of the
17th stage wheel, thus connecting the distance
piece to the wheel. The aft wheel shaft is
connected to the load gearbox coupling. It also
includes the bearing journal no-2
4 Stage Typical Gas Turbine
17 Stage Axial Compressor
• Cooling of Buckets
As the first stage buckets are the first to
encounter the extremely hot gases, hence
longitudinal holes are provided in these buckets
for cooling as air pressure is passed through the
holes.
• Turbine Rotor Cooling
Rotor cooling is done by means of a positive flow
of cool air radially outward through a space
between the wheel and the buckets, then through
the stator and finally into the main gas stream
area, which is, called wheel space.
• First Stage Wheel Space Cooling
The forward wheel space cooling is done by
compressor discharge air, which is leaking
through the labyrinth. This air discharges in to the
main gas stream. The aft wheel space is cooled
by 2nd stage nozzle cooling air.
• Second Stage Wheel Space Cooling
Forward wheel space is cooled by leakage from
1st stage aft wheel space through the inter stage
labyrinth. Aft wheel space is cooled by air from the
internal extraction system. This air enters the
wheel space through slots in the forward face of
the spacer.
• Exhaust Frame
Exhaust diffuser is provided in the exhaust frame where
exhaust gases from third stage of turbine enters. Diffuser
reduces the velocity and pressure is recovered. At the exit
of diffuser turbine vanes assist in directing the gases into
the exhaust frame.
• Bearings
The Gas turbine unit contains two main journal bearings
used to support the gas turbine rotor. Bearing no-1
subassembly includes two thrust bearings. These main
bearings are pressure lubricated by lube oil, supplied by
lube oil system. The seals provided in the bearing housing
prevent the lube oil from being spun along with the shaft
and the pressurized sealing air prevents lubricating oil
from spreading along the shaft. Some of the air returns
along with the lube oil through the lube oil drain pipe to the
main reservoir and is finally vented through vent.
 Nozzles
• There are three stages of stationary nozzles, which direct
the high velocity flow of the hot gases against turbine
buckets causing the turbine rotation.
• 1st stage nozzle: It receives the hot gases from the
combustion system via the transition pieces
• 2nd stage nozzle: Combustion air exiting from the first
stage buckets is again expanded and redirected against
the second stage turbine buckets by the second stage
nozzles. The second stage nozzle is cooled with
compressor discharge air.
• 3rd stage nozzle: the third stage receives the hot gas as it
leaves the second stage buckets increase its velocity by
pressure drop, and directs this flow to impinge against the
third stage buckets.
Nozzles
 GAS TURBINE SUPPORT SYSTEMS
• Two main turbine bearings.
• Generator bearings.
• Reduction gear.
• Turbine accessory gear.
• Control fluid for hydraulic control devices.
• The lubrication system components include;
1. Lube oil tank in the turbine base
2. Main lube oil pump (shaft driven from accessory gear)
3. Auxiliary lube oil pump
4. Emergency lube oil pump
5. Pressure relief valve in the main pump discharge
6. Lube oil heat exchangers
7. Main lube oil filters.
8. Bearing header pressure regulator
 GAS TURBINE SUPPORT SYSTEMS
• The main oil pump (MOP) is a positive discharge
pump, driven by accessory gear and installed at inboard
wall of lower half casing of accessory gear. Capacity-
1741 LPM & Normal discharge pressure- 4.7 to 5.0
kg/cm2
• Auxiliary oil pump (AOP) is an AC driven submerged
centrifugal lube oil pump. Capacity- 1741 LPM & Normal
discharge pressure- 4.2 to 4.7 kg/cm2
• Emergency oil pump (EOP) is a DC driven submerged
centrifugal lube oil pump. It normally runs in case of
failure of AOP or AC power. During startup (if required) it
operates until GT reaches nearly 40 % of rated speed
and it will continue to operate if desired pressure is not
achieved. Capacity- 946 LPM & Normal discharge
pressure- 0.42 + 0.07 kg/cm2
• Lube oil heat exchangers is provided to cool the lube
oil circulating in the system.
 Cooling Water System
It cools the both on base and off components of
gas turbine. In gas turbine, the cooling water (pr
= 2.0 - 2.5 kg/cm2) circulates water as a cooling
medium to perform following functions:
• Heat dissipation requirement of lubrication
system
• Generator air cooler.
• Turbine support legs cooling.
• Diesel engine water to water heat exchanger
• Atomizing air water to water heat exchanger
 STEAM TURBINE
Three steam turbines drive equal
numbers of electricity generators,
produce 30 MW each. Steam turbines are
supplied with from VHP Boiler at a
pressure of 100Kg/cm2 and temperature
of 500 deg C and work in integration with
a process steam grid
STEAM TURBINE TECHNICAL DATA
1. Max. Continuous rating KW 25,000
2. Most economical rating KW 25,000
3. Zero extraction rating KW NA
4. Turbine normal speed 3,000 RPM
5. Turbine trip speed 3,300 RPM
6. Direction of rotation Clock Wise
7. No. of bleedings Two
8. No. of externally controlled extraction’s One
9. Design standard IEC 45
10. Number of casings One
11. Turbine installation Indoor
12. Speed regulation 4-6 %
13. Governor band 88 - 107 %
14. Press. Controller type Electric
15. Type of machine EXTRN. Condensing
16. Governor type Electro Hydraulic with Hydraulic
 Steam Flow Cycle
1. VHP boiler (pr = , temp = 510 deg C)
supply steam to header I and II & in turn
to turbine Valves controlled by the
governing system
2. Turbine has 3 extractions;
• Extraction I - MP steam header
• Extraction II - LP steam header
• Extraction III – VLP - LPH
 GOVERNING SYSTEM
The turbine set is equipped with electro
hydraulic governing system with
hydraulic back up. The governing system
is designed to control the speed of turbo
generator set at varying electrical loads
and extraction steam quantities
• Emergency Stop Valve
• HP Control Valves
• Steam extraction
 Turbine Oil System
• Oil tank
• Main oil pump
• Auxiliary oil pump (AOP)
• Oil cooler
• Oil filter
• Emergency oil pump (EOP)
• Oil vapour extraction fan
• Jacking oil system
• Turbine barring
 BARRING MOTOR
Turbine
MOP EX
GEN
Oil
System

COOLER FILTER

AC JOP

AOP EOP DC JOP

• Steam expands, whenever it is subjected either to
lower pressure or to a higher temperature.
• It is considered to be free expansion when the
expanding boundary is free from any resistance
from the surrounding. Though the free expansion
has no engineering application but it provides
enough guidelines to the designers of steam
turbines/engine to properly deal with steam
operating parameter to avoid any possibility of free
expansion.
• Expanding steam (thermodynamic System) does
work on surrounding irrespective of its being a
solid, liquid or gas separated by well defined
boundary.
• Expansion of steam in turbine is facilitated to do
work on turbine blades mounted on the freely
rotating shaft.
When steam is allowed to expand through a nozzle, then its
heat is converted to kinetic energy of steam itself, which in
turn converts into kinetic energy (mechanical energy) of
Turbine Rotor through the impact (impulse) or in an other
way, when it expands through Turbine Rotor Blades without
any change in its velocity then its heat is converted directly
in to kinetic energy (mechanical energy) of Turbine Rotor
through reaction of steam expansion against the blades.

• Impulse Turbine (DR = 0)

• Reaction Turbine (DR = 1)
• Impulse - Reaction Turbine (DR > 0 & <1)
 Components of Steam Turbine
• Foundation (TG & Pillar)
• Base plate / sole plate
• Bearing pedestal / pedestal plate
• Casing
• Single / double (Inner or outer casing) / Triple
casing
• Barrel type or axially spilt (bottom or top flange)
• Body liners and stationary diaphragm
• Rotor
• Inbuilt (solid), key & shrunk fit and welded
• Moving diaphragm
• Studs and nuts
 Components of Steam Turbine
• HP, IP & LP turbine.
• Bearings.
• Shaft sealing .
• Stop & control valves.
• Turbine control system.
• Turbine monitoring system.
• Turbine oil system.
• Turbine turning gear
Foundation
Stationary Diaphragm
Steam Turbine Blades
Vector Diagram
Multistage Turbine Blade Arrangement
Multistage Turbine Blade Arrangement
3
Steam Turbine Rotor with 2 Imp Stages
LP Rotor of 210 MW KWU Turbine
 β2 Velocity Vector Diagram
α2
for Pure Impulse Turbine

β1
α1

α2 α1 β2 β1
 Blade Performance of Pure Impulse Turbine

Wo = C2 Cos α2 (clockwise tangential component)

Wi = C1 Cos α1 (anticlockwise tangential component)
R2 < R1 & R2 = µ*R1
For smooth surface µ = 1 & R2 = R1
P = [Wi - (-Wo)]*u = [C2 Cos α2 + C1 Cos α1]*u
C2 Cos α2 = R2 Cos β2 –u = R1 Cos β1 –u
or C2 Cos α2 = C1 Cos α1 - u – u = C1 Cos α1 – 2u
P = [C1 Cos α1 + C1 Cos α1 – 2u]*u = 2*u*[C1 Cos α1 – u]
ηb = 2*P/C1**2 = 4*[(u/C1)*Cos α1 – (u/C1)**2]
 α2 β2 Velocity Vector
Diagram for
β1 α1 Impulse-Reaction
Turbine

α2 α1 β2 β1
Work Done in Imp-Reaction Steam Turbine
Deduction of C2 & R1 in terms of R2 & C1
Stage Efficiency
Internal Losses
 CONDENSER
The surface condenser is a shell and tube
nest arrangement with water boxes at
either end. The steam side of the surface
condenser is connected to the exhaust
hood of the turbine. The tube plates
separate the water chambers from the
steam space. The condensate is
extracted from the hot well by the
condensate extraction pumps.
Starting/Main Ejector Flow Circuit
 Functions of The Condenser
• To condense the steam exhausted from the turbine
• To maintain vacuum such that the heat drop to be
utilized in the turbine is a maximum
• To maintain the temperature of the condensate always at
the saturation temperature so that all dissolved gases
are liberated
• To form convenient point for introducing make-up water
• To prevent the under cooling of the condensate so that
the thermal losses are minimized
• To facilitate the extraction of air and other gases.
 Condensate/Feed Water System

• CEP
• Main Ejector
• Gland Steam Condenser
• Low Pressure Heater
• Deaerator & Storage Tank
• BFP
• High Pressure Heater