Summer Project Report (Prakhar Gupta, A2305106167)

DCC
PP
Submitted in partial fulfilment of the requirements for the award of the degree of Bachelor of Technology In Electronics & Communication Engg.
Supervisor: Mr. H.P. SINGH Mrs. EILA SHARMA
Submitted By: Mr. PRAKHAR GUPTA B.Tech ECE ,21008
AMITY SCHOOL OF ENGINEERING TECHNOLOGY, NOIDA AMITY UNIVERSITY UTTAR PRADESH (2006-10)
1|Page Familiarization w ith DCCPP (Dholpur Combined Cycle Power Project )
CERTIFICATE
This is to certify that the dissertation entitled Familiarization w ith DCCPP is being submitted by PRAKHAR GUPTA ( A2305106167) in partial fulfillment for the award of the degree of Bachelor of Technology in Electronics and Communication Engi nee ring to the Amity University has been carried out by them under our guidance and supervision. The results embodied in this thesis have not been submitt ed to any other Uni versity or Institution for the awar d of any other degree by them.
Date:
Supervisor:
Mr. H.P. SINGH
Mrs. EILA SHARMA
ACKNOWLEDGEMENT
Setting an endeavor may not always be an easy task; obstacles are bound to come in its way and when this happens, help is welcome and needless to say without help of those people whom I am mentioning here, this endeavor would not have been successful. My primary obligation is to Mr. S.B. GUPTA (Chief Engg.) who provided me the opportunity and platform to undergo summer training in Dholpur Combined Cycle Power Project (D.C.C.P.P.),DHOLPUR [Raj.]
During my project work many helping hands came across my way, I would like to acknowledge my sincere and endless gratitude to them. First and foremost I express my deep sense of gratitude to Mr. R.C. Meghwal (XEN Opr.) for his constant advice and valuable time he has given to me for my project. They encouraged me to put forward my best effort towards the completion of this project. I would also like to extend my special thanks to Mr. S.B. Meena (XEn) and Mr. Gaurav(JEn) for his support at every step. I am very much thankful to each and every member of DCCPP who helped me during the course of training.
I am thankful from the core of my heart for the precious contribution of DG Mam, HOD and faculty guides Mr. H.P. Singh and Mrs. Eila Sharma of ASET who provided their best possible help. The successful completion of this training has been possible due to sincere co-operation, guidance, inspiration, moral support and timely advice of each and every one who devoted their utmost co-operation in this training.
PRAKHAR GUPTA
ABSTRACT
DCCPP is situated in the outskirts of Dholpur which is about 55Km. South West of Agra. DCCPP is a Project of Rajasthan Rajya Vidhyut Utpada Nigam Ltd.
The total estimated cost of the plant is Rs. 1155 crore. The main equipments were supplied by M/s BHEL and it was also the main contractor for erection, testing and commissioning of the plant. The BOP (Balance of plant) was given to M/s GEA Energy System. The main fuel used for this plant is R-LNG (liquified natural gas) which will be supplied by M/s GAIL. The gas required per day for both units is 1.3MM SCM at 9000Kcal.
The unique feature of this plant is that waste heat from the gas turbine is recovered by a heat recovery steam generator to power a conventional steam turbine in a combined cycle configuration. And also a MARK- 6 control system has been introduced for the first time in the northern region in INDIA.
CONTENTS
Chapter Title Page No.
Chapter 1.
Introduction Of The Organisation 1.1 Dholpur Combined Cycle Power Project (DCCPP) 1.2 Working Principle of Combined cycle Power Plant 1.2.1 Method of Transforming other power into electrical power 1.3 Selection of site for the Gas Power Plant 1.4 Features of the Plant 1.5 Plant Lay Out 12 13 15 17 11 10
Chapter 2.
Gas Turbine (GT) 2.1 Working of Gas Turbine (GT) 2.2 Theory of Operation 2.2.1 Gas Power Cycle 2.2.2 Bray ton Cycle
18 19 20 21 21
Chapter 3.
Heat Recovery Steam Generator (HRSG) 3.1 HRSG 3.2 Application of HRSG 26 28
3.3 Component of HRSG 3.3.1 Economizer 3.3.2 Superheater 3.3.3 Evoporator 3.4 Salient Features of HRSG 3.5 Arrangement of HRSG DCCPP Plant 3.6 Working of HRSG 3.7 Specification of Boiler Drums
29 30 31 31 32 34 35 36
Chapter 4.
Steam Turbine (ST) & Condenser 4.1 Steam Turbine (ST) 4.2 Advantages & Losses of ST 4.3 Working of ST 4.4 Condenser 4.5 Element of a Condensing Plant 37 37 39 40 41
Chapter 5.
Combined Cycle Power Generation 5.1 Combined Cycle Electricity Generation 5.2 Advantages &Disadvantage. Of Combined Power Plane 5.3 Classification of CCGPP 5.4 Environmental effect of Combined Cycle Electricity Generation 5.5 Working of a CCPP 5.5.1 Power Generation 5.5.2 Emission Control 5.5.3 Transmission of Generated Power 43 45 46 48 49
6|Page
42
42 43
Familiarization w ith DCCPP (Dholpur Combined Cycle Power Project )
5.6 Water Tanks, Natural Gas Pipeline & Control Room 50
Chapter 6. Water Clarification cum Filtration Plant & Turbo Generator and Extation System 6.1 Water Clarification cum Filtration Plant 6.1.1 Various Process that are involved in Treatment of Water 6.1.2 DeMineralizing Plant (DM Plant) 6.1.3 Degassifire 6.1.4 Weak base Anion Tank 6.1.5 Polishinging Unit 6.1.6 DM Water Quality 6.1.7 Water Softner 6.1.8 Analyzer DM Plant 6.1.9 CW Pump House 6.1.10 Water Classifier 6.2 Turbo Generator and Excitation System 6.2.1 Theory behind the working of a Turbogenerator 6.2.2 Main Component of Generator 6.2.3 Functions of excitation System 6.2.4 Brushless Excitation System 59 60 60 60 53 54 55 55 55 56 56 56 58 58 59 53
Chapter 7.
220KV Switchyard & Transformer and Maintenanc Work 7.1 220KV Switchyard 7.1.1 Bus Scheme 7.1.2 Bus System 7.1.3 SF6 Gas Circuit breakers 7.1.4 Isolator 7.2 Transformers 7.2.1 Current and Capacitive voltage Transformer 7.2.2 Lightning Arrestor and Arc Horns 7.2.3 Change over Schemes(Bus the Sys.) 7.2.4 Synchronization of the Generator To the Grid 66 65 65 65 62 62 63 63 65 65
7.3 Maintenance Job to be Done on 220 KV Switchyard 7.3.1 Daily Job 7.3.2 Monthly Job 7.3.3 Quarterly Job 7.3.4 During annual ShutDown of Unit 67 67 68 70
Chapter 8. DC System & Power Line Communication 8.1 DC System 8.1.1 Batteries 8.1.2 Switchyard Building Battery bank 8.1.3 Battery Room 8.1.4 Electrolyte 8.1.5 Temperature Correction
73 73 73 73 74 74
8|Page
8.1.6 Normal operation of Batteries
74
8.2 Power line carrier Communication 8.2.1 Earth Shielding 8.2.2 Working
75 75 76
RESULT AND CONCLUSION
77
BIBLIOGRAPHY
CHAPTER-1 INTRODUCTION OF THE ORGANISATION

1.1 DHOLPUR COMBINED CYCLE POWER PROJECT DCCPP is situated in the outskirts of Dholpur which is about 55Km. South West of Agra. Dholpur was considered an ideal location for setting up of a gas power plant having regards to the availability of land, water, transmission network, proximity to broad gauge railway , also well connected by roads (G.T. road passes through this city) and being an important load center for eastern Rajasthan.
The total estimated cost of the plant is Rs. 1155 crore. The main equipments were supplied by M/s BHEL and it was also the main contractor for erection, testing and commissioning of the plant. The BOP (Balance of plant) was given to M/s GEA Energy System. The main fuel used for this plant is R-LNG (liquified natural gas) which will be supplied by M/s GAIL. The gas required per day for both units is 1.3MM SCM at 9000Kcal.
The unique feature of this plant is that waste heat from the gas turbine is recovered by a heat recovery steam generator to power a conventional steam turbine in a combined cycle configuration. And also a MARK- 6 control system has been introduced for the first time in the northern region in INDIA.
A combined cycle is characteristic of a power producing engine or plant that employs more than one thermodynamic cycle. Heat engines are only able to use a portion of the energy their fuel generates (usually less than 50%). The remaining heat from combustion is generally wasted. Combining two or more "cycles" such as the Brayton cycle and Rankine cycle results in overall improved efficiency.
10 | P a g e Familiarization w ith DCCPP (Dholpur Combined Cycle Power Project )
In a combined cycle power plant (CCPP), or combined cycle gas turbine (CCGT) plant, a gas turbine generator generates electricity and the waste heat is used to make steam to generate additional electricity via a steam turbine; this last step enhances the efficiency of electricity generation. Most new gas power plants in North America and Europe are of this type. In a thermal power plant, high-temperature heat as input to the power plant, usually from burning of fuel, is converted to electricity as one of the outputs and lowtemperature heat as another output. . As a rule, in order to achieve high efficiency, the temperature difference between the input and output heat levels should be as high as possible (see Carnot efficiency). This is achieved by combining the Rankine (steam) and Brayton (gas) thermodynamic cycles. Such an arrangement used for marine propulsion is called Combined Gas (turbine) And Steam (turbine) (COGAS).
1.2 WORKING PRINCPLE OF COMBINED CYCLE POWER PLANT In a steam power plant water is the working medium. High pressure steam requires strong, bulky components. High temperatures require expensive alloys made from nickel or while the lower temperature of a stem plan is fixed by the boiling point of water. With these cobalt, rather than inexpensive of steel. These alloys limit practical steam temperatures to 655 limits, a steam plant has a fixed upper efficiency of 35 to 40%. For gas turbines these limitations do not apply. Gas cycle firing temperatures above 1,200 C are practicable. So, a combined cycle plant has a thermodynamic cycle that operates between the gas-turbines high firing temperature and the waste heat temperature near the boiling point of water.
1.2.1 Method for transforming other power in to electrical power :Rotating turbines attached to electrical generators produce most commercially available electricity. Turbines may be driven by using steam. Water wind or other fluids as an intermediate energy carrier. The most common usage is by steam in fossil fuel power plants or nuclear power plants and by water in hydroelectric dams. Alternately turbines can be driven directly by the combustion of natural gas. Power plants are classified in the following categories according to the fuel used: (a) Coal based thermal power plant (b) Nuclear power plant (c) Hydro electric power plant (d) Solar power plant (e) Wind power plant (f) Gas power plant
Electricity From Natural gas :Power plant uses several methods to convert gas into electricity. One method is to burn the gas in a boiler to produce steam, which is then used by a steam turbine to generate electricity. A more common approach is to burn the gas in a combustion turbine to generate electricity. Another technology that is growing in a combustion turbine and used the hat combustion turbine exhaust to make steam to drive a steam turbine. This technology is called combined cycle and achieves a higher efficiency by using the same fuel source twice.
1.3 SELECTION OF SITES FOR THE GAS POWER PLANT

1. SUPPLY OF WATER
A large quantity of water is required in steam power plants. It is required: (I) (II) (III) (IV) It raises the steam in the boiler. For cooling purposes such as in condensers. As a carrying medium such as in disposal of ash. For drinking purposes.
The efficiency of direct cooled plant is about 0.5% higher than that of the plant in which cooling towers are used. This means a saving of about Rs. 7.5 lakhs per year in fuel cot for a 2000 MW station
2. REQUIREMENT OF LAND
The land is required not only for setting up of the plant but also for other purposes such as staff colonies, coal storage, ash disposal etc. cost of land adds to the final cost of the plant. So it should be available at a reasonable cost. Land should be of good bearing capacity since it has to withstand about 7 Kg. per Sq. Cm. Moreover, land should be reasonably level. It should not be low lying.
3. TRANSPORTATION FACILITY
The land and rail connections should be proper and capable of taking heavy and over dimensioned loads of machines etc. To carry coal, oil etc. which are daily requirements, we need these transport linkages.
4. LABOUR SUPPLIES
Skilled and unskilled laborers should be available rates near the site the plant.
5. ASH DISPOSAL
Ash is the main waste product of the steam power plant. Hence some suitable means for disposal of ash should be applied. Ash can be purchased by building contractors, cement manufacturers or it can be used for brick making near the plant site. Otherwise wasteland should be available near the plant site for disposal of ash.
6. DISTANCE FROM THE POPULATED AREA
Since most of the modern generating stations employ pulverized fuel residues and fumes from them are quite harmful. Therefore the site for the plant should be away from the populated area.
7. CLIMATIC CONDITIONS
Climate conditions of a place play a significant part in economics of capital investment.
1.4 FEATURES OF THE PLANT
Two 250 MW Turbo-generator sets together with two boilers machine capacity along with associate auxiliaries. The boilers are of natural circulation water tube single drum pulverized fuel fired, dry bottom, balanced draft type using the direct firing system. The steam turbines are of tandem compound operating on reheat and regenerating cycle and condensing type. The turbo-generators. The cooling of stator is done by means of Dimeneralized water and rotor by hydrogen. Brushless excitation system has been provided.
TECHNICAL DATA: 1. COST OF THE PLANT Rs. 1155.15 Crore (STAGE-1)
2. DATE OF SYNCHRONIZATION: UNIT 1 1sep2007__UNIT 2 1sep2007__UNIT 3 1 Jan 2008 __
3. CHIMNEY HEIGHT Unit: 1, 2 220 Mt
4. WATER REQUIREMENT 400 m / hr (3 x 110m.w.)
BOILER Type Capacity Make Steam Temperature Steam Pressure

GENERATOR Make Type Capacity Kva Stator Voltage Current Rotor Voltage Current Power Factor Speed Frequency Phase Connection Coolant Gas Pressure Insulation Hydrogen 3 Bar Class F 319 Volt 2386amp 0.85 Lag. 3000 Rpm 50 Hz 3 16,500 Volt 10,290 Amp
high pressure boiler drum 780 tons/hr BHEL 550 c 150 kg /cm2
Bhel Tg -Hh-0250-2 250mw 294100 Kva
1.5 PLANT LAY OUT
CHAPTER-2 GAS TURBINE (GT)
A gas turbine extracts energy from a flow of hot gas produced by combustion of gas or fuel oil in a stream of compressed air. It has an upstream air compressor (radial or axial flow) mechanically coupled to a downstream turbine and a combustion chamber in between. Gas turbine may also refer to just the turbine element.
2.1 WORKING OF GAS TURBINE
DCCPP located at Dholpur has a unique feature that the same energy source (i.e. natural gas) is used to rotate both gas and steam turbine without wasting much of energy. As the name implies it is a combined cycle i.e. waste heat from the gas turbine is recovered by a heat recovery steam generator to power a conventional steam turbine in a combined cycle configuration. Hence, the working of both gas and steam turbine is discussed here.
A gas turbine, also called a combustion turbine, is a rotary engine that extracts energy from a flow of hot gas produced by combustion of gas in a stream of compressed air. It has an upstream air compressor radial or axial flow mechanically coupled to a downstream turbine and a combustion chamber in between. Gas turbine may also refer to just the turbine element.
Energy is released when compressed air is mixed with fuel and ignited in the combustor. The resulting gases are directed over the turbine's blades, spinning the turbine, and, mechanically, powering the compressor. Finally, the gases are passed through a nozzle, generating additional thrust by accelerating the hot exhaust gases by expansion back to atmospheric pressure.
Energy is extracted in the form of shaft power, compressed air and thrust, in any combination, and used to power electrical generators.
2.2 THEORY OF OPERATION
Gas turbines are described thermodynamically by the Brayton cycle, in which air is compressed isentropically , combustion occurs at constant pressure, and expansion over the turbine occurs isentropically back to the starting pressure. In practice, friction, and turbulence cause: a) Non-isentropic compression: for a given overall pressure ratio, the compressor delivery temperature is higher than ideal. b) Non-isentropic expansion: although the turbine temperature drop necessary to drive the compressor is unaffected, the associated pressure ratio is greater, which decreases the expansion available to provide useful work. c) Pressure losses in the air intake, combustor and exhaust: reduces the expansion available to provide useful work.
2.2.1 Gas Power Cycle

although any cycle may in principle be used as a heat engine or as a refrigerator and heat pump by just reversing the direction of the process in practice there are big difference and the study is split between power cycle and refrigeration cycle. Many gas cycle have been proposed and several are currently used to model real heat engines. From the academic point of view we will the brayton cycle.
2.2.2 Bray ton Cycle:-
The Brayton Cycle nomad after the American engineer George bray ton is a good model for the operation of a gas turbines engine. Now a days used by practically all aircraft except the smallest once by fast boast and increasingly been used for stationary power generation.
Particularly when both power and heat are of interest the ideal bray ton cycle in the T-S and P-V diagram and the regenerative cycle. As with all cyclic heat engines, higher combustion temperature means greater efficiency. The limiting factor is the ability of the
steel, nickel, ceramic, or other materials that make up the engine to withstand heat and pressure. Considerable engineering goes into keeping the turbine parts cool.
Most turbines also try to recover exhaust heat, which otherwise is wasted energy. the heat released from the exhaust gas has been absorbed by many kms of tubing which line the boiler. Inside these tubes is water, which takes the heat and is converted into steam at high temperature and pressure. The type of boiler is called heat recovery steam generation (HRSG) This steam at high temperature and pressure is sent to the turbine where it is discharged through the nozzles on to the turbine blades.
The energy of the steam striking on the blades makes the turbine to rotate. Coupled to the turbine is the rotor of the generator. So when the turbine rotates the rotor of the generator turns. The rotor is housed inside a stator having heavy coils of copper bars in which electricity is produced through the movement of magnetic field produced by the rotor. Electricity passes from stator winding to the transformer, which increases its voltage level so that it can be transmitted over the lines to far off places.
The steam, which has given away its energy, is changed back into water in the condenser. Condenser contains many kms of tubing through which cold water is continuously pumped. The steam passing over the tubes continuously loses heat and is rapidly changed back into water. But the two waters i.e. the boiler feed water and cooling water must never mix. Boiler water must be absolutely pure otherwise the tubing of the boiler may get damaged due to the formation of salts inside the tubes due to the presence of different impurities in water.
To condense large quantities of steam huge and continuous volume of water is required. In some power stations same water has to be used again and again because there is not enough water. So the hot water tracts are passed through the cooling towers. The cooling
towers are simply concrete shells acting as a huge chimney creating a draught of air. The design of cooling towers is such that a draught of air is created in the upward direction. The water is sprayed at the top of the tower. As it falls down the air flowing in the upward direction cools it. The water is collected in a pond from where the water is recirculated by the pumps to the condenser. Inevitably, however some of the water is taken taken away by the draught of water in the form of vapours and it is this water with familiar white clouds emerging from the cooling towers.
AnOther One:
Mechanically, gas turbines can be considerably less complex than internal combustion piston engines. Simple turbines might have one moving part: the
shaft/compressor/turbine/alternator-rotor assembly (see image above), not counting the fuel system.
As a general rule, the smaller the engine the higher the rotation rate of the shaft(s) needs to be to maintain tip speed. Turbine blade tip speed determines the maximum pressure that can be gained, independent of the size of the engine.
Thermal power station burn fuels and use the resultant steam to drive the turbo generator. The object is to convert heat into mechanical energy in the turbine and to convert mechanical energy into electrical energy by rotating magnets inside a set of magnets. The coal brought to the station by means of trains travel from the coal handling plant by conveyor belts to the coal bunkers. From where it is fed to pulverizing mills which grind it to a fine powder. Finely powdered coal mixed with preheated air is blown into the boiler by primary air fan where it burns more like a gas than as a solid with additional amount of air called the secondary air supplied by the secondary draft fan.
As the coal has been ground finely the resultant ash is fine powder. Some of its contents bind together to form lumps which fall in ash pits at the bottom of the furnace. The ash mixed with water is then taken to the pits for subsequent disposal. The electrodes charged by high voltage electricity in the electrostatic precipitator trap most of the ash. The dust is then conveyed by water to the disposal area or to the bunkers while the cleaned flue gases pass on through the ID fan to discharge through the chimney. Meanwhile the heat released from the burning of coal has been absorbed by many kms of tubing which line the boiler. Inside these tubes is water, which takes the heat and is converted into steam at high temperature and pressure.
This steam at high temperature and pressure is sent to the turbine where it is discharged through the nozzles on to the turbine blades. The energy of the steam striking on the blades makes the turbine to rotate. Coupled to the turbine is the rotor of the generator. So when the turbine rotates the rotor of the generator turns. The rotor is housed inside a stator having heavy coils of copper bars in which electricity is produced through the movement of magnetic field produced by the rotor. Electricity passes from stator winding to the transformer, which increases its voltage level so that it can be transmitted over the lines to far off places.
The steam, which has given away its energy, is changed back into water in the condenser. Condenser contains many kms of tubing through which cold water is continuously pumped. The steam passing over the tubes continuously loses heat and is rapidly changed back into water. But the two waters i.e. the boiler feed water and cooling water must never mix. Boiler water must be absolutely pure otherwise the tubing of the boiler may get damaged due to the formation of salts inside the tubes due to the presence of different impurities in water.
To condense large quantities of steam huge and continuous volume of water is required. In some power stations same water has to be used again and again because there is not enough water. So the hot water tracts are passed through the cooling towers. The cooling towers are simply concrete shells acting as a huge chimney creating a draught of air. The design of cooling towers is such that a draught of air is created in the upward direction. The water is sprayed at the top of the tower. As it falls down the air flowing in the upward direction cools it. The water is collected in a pond from where the water is recirculated by the pumps to the condenser. Inevitably, however some of the water is taken away by the draught of water in the form of vapours and it is this water with familiar white clouds emerging from the cooling towers.
CHAPTER-3 HEAT RECOVARY STEAM GENERATOR (HRSG)
3.1 HRSG
A heat recovery steam generator or HRSG is a heat exchanger that recovers heat from a hot gas stream. It produces steam that can be used in a process or used to drive a steam turbine. A common application for a HRSG is in a combined-cycle power station, where hot exhaust from a gas turbine is fed to an HRSG to generate steam which in turn drives a steam turbine. This combination produces electricity more efficiently than either the gas turbine or steam turbine alone. The HRSG is also an important component in cogeneration plants. Cogeneration plants typically have a higher overall efficiency in comparison to a combined cycle plant. This is due to the loss of energy associated with
HRSGs consist of three major components. They are the Evaporator, Superheater, and Economizer. The different components are put together to meet the operating requirements of the unit. See Modular HRSG GA.
Modular HRSGs normally consist of three sections: an LP (low pressure) section, a reheat/IP (intermediate pressure) section, and a HP (high pressure) section. Each section has a steam drum and an evaporator section where water is converted to steam. This steam then passes through superheaters to raise the temperature and pressure past the saturation point.
Packaged HRSGs are designed to be shipped as a fully assembled unit from the factory. They can be used in waste heat or turbine (usually under 20MW) applications. The packagaged HRSG can have a water cooled furnace which allows for higher supplemental firing and better overall efficiency.
Some HRSGs include supplemental, or duct, firing. These additional burners provide additional energy to the HRSG, which produces more steam and hence increases the output of the steam turbine. Generally, duct firing provides electrical output at lower capital cost. It is therefore often utilized for peaking.
HRSGs can also have diverter valves to regulate in the inlet flow into the HRSG. This allows the gas turbine to continue to operate when there is no steam demand or if the HRSG needs to be taken offline.
Emissions controls may also be located in the HRSG. Some may contain a Selective Catalytic Reduction system to reduce nitrogen oxides (a large contributor to the formation of smog and acid rain) and/or a catalyst to remove carbon monoxide. The inclusion of an SCR dramatically affects the layout of the HRSG. NOx catalyst performs best in temperatures between 650F and 750F. This usually means that the evaporator section of the HRSG will have to be split and the SCR placed in between the two sections. Some low temperature NOx catalysts have recently come to market that allows for the SCR to be placed between the Evaporator and Economizer sections (350F500F).
3.2 APPLICATIONS OF HRSG

Heat recovery can be used extensively in energy projects. In the energy-rich Persian Gulf region, the steam from the HRSG is used for desalination plants.
Universities are ideal candidates for HRSG applications. They can use a gas turbine to produce high reliability electricity for campus use. The HRSG can recover the heat from the gas turbine to produce steam/hot water for district heating or cooling.
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3.3 COMPONENT & ARRANGEMENT OF HRSG
There are two boiler drums in HRSG-
1.High pressure drum 2.Low pressure drum There are deviation in boiler drums . Steam accumulated in upper part of drum water in the lower part of the drum water is drawn out by a pipe at the bottom of the drum If there are excess pressure and temperature. Then to remove these there are two controlling arrangements 1.Pressure controlling arrangement.-pressure safety valves like pressure cooker whistle loaded there and design to release excess pressure. 2.temprature controlling arrangement-a Dshape pipe is there for control the excess temp. If temp. exceed demineralized water is sprayed in it. And the temp. lowered There are two HRSG plant for two gas turbine. The combined steam of HRSG-1& HRSG-2 produce the power of 110MW. In a boiler drum there are riser pipes. from which steam comes into the drum. HP drum is bigger then LP drum
There are three main components of HRSG 1.Economisers 2.superheaters 3.evoporator

3.3.1 Economiser
The greatest item of heat loss in a boiler plant is that pf the heat is carried away in the flue gases of the chimney stack. some of this heat may be recovered and sent back into the boiler in the feed water by an economizer a saving of 10 percent.
The advantage of economizer are
1. increase the efficiency of boiler plant 2. reduce the range of temp.b/w different parts of boiler and hence reduces the stress due to unequal expansion 3. more rapid evaporation and hence quicker circulation of water making the heating surface increase the efficiency of boiler plant 4. reduce the range of temp.b/w different parts of boiler and hence reduces the stress due to unequal expansion 5. more rapid evaporation and hence quicker circulation of water making the heating more effective
Disadvantage of economiser
1. there is a loss of draught for the flue gases and natural draught is un sufficient. the plant has to provided with an artificial draught equipment
3.3.2 Superheater
A superheater is a device used to convert saturated steam into dry steam used for power generation or processes. There are three types of superheaters namely: radiant, convection, and separately fired. A superheater can vary in size from a few tens of feet to several hundred feet (a few meters or some hundred meters) It is surface heat exchanger in which the heat of the combustion product is utilized first to dry wet steam and then to raise the temp. in super heater there is no change of pressure of steam but its volume increased and temp is raised.
3.3.3 Evoporator
Within a downstream processing system, several stages are used to further isolate and purify the desired product. The overall structure of the process includes pre-treatment, solid-liquid separation, concentration, and purification and formulation. Evaporation falls into the concentration stage of downstream processing and is widely used to concentrate foods, chemicals, and salvage solvents. The goal of evaporation is to vaporize most of the water from a solution containing a desired product. After initial pre-treatment and separation, a solution often contains over 85% water. This is not suitable for industry usage because of the cost associated with processing such a large quantity of solution, such as the need for larger equipment
Evoporator-in this phase change is done .in this water change into steam
3.4 SALIENT FEATURES OF HRSG

Horizontal Natural Circulation Design. Steam generation at multiple pressure levels with or without reheaters. Modular construction with spiral finned tubes for compactness. Fully drainable heat transfer section Short installation time. Ease of operation. Supplementary Fuel firing system to meet specific customer requirements. o -In duct firing/Furnace firing. o Multiple Fuel firing (Oil/Gas).
Low NOx and CO emission. o Stand by fresh air firing with FD fan for uninterrupted steam supply ( FD Fan mode ).
Unfired boiler. Exhaust gases are used to generate steam. 500 c lower portion. High pressure circuit two. 6H bar upper portin economizer. Low temperature portion. 6 bar 202 c (ragging) Discharge pressure 1H bar steam Water tube boiler. Forced circulation boiler. Vertical boiler. At 100 c leaver boiler. Deareater feed storage tank
Circuit Economizer Evaporator Super heater Twin cyclender turbine. Tendon compound turbine.
feed regulating station controls flow H.P. turbine and L.P. turbine
HP STEAM (RATED PARAMETERS) PRESSURE : 78.2 Kg/Cm2. TEMPERATURE : 514+/- 5 Deg. C FLOW : 187.1 TPH.
LP STEAM (RATED PARAMETERS) PRESSURE : 5.0 Kg/Cm2. TEMPERATURE : 200 Deg. C FLOW : 39.8 TPH.
3.5 ARRANGEMENT OF HRSG DCCPP PLANT
3.6 WORKING OF HRSG

In this the water used in steam generation is de mineralized water .because steam of DM water not contains any particles and minerals. If these substances present in steam it may be harmful for turbine blades.
From a water reservoir water is supplied in water clarifier .then supplied in DM plant in which water is undergoes too many chemical reactions with diff. chemicals to remove its impurities & minerals after which is supply to the plant.
First of all dm water comes in economizer so that increase the temp. of water. in this the hot flue gases passes over exterior of tubes. heating of feed water by 1deg.c permits reducing the temp. of flue gases by 2to3 deg. By this efficiency of boiler is increased.
After this water is supplied to boiler drum then evaporator. In this water is converted into steam. this steam is wet steam. then this steam passes through superheaters to raise the timpani pressure past the saturation point. by this dry steam is getting after this steam is supplied to boiler drum and then steam turbine.
Wet steam may be harmful to turbine blades. So superheated steam is used to turbine.
There are so many modules of components of HRSG. These are alloy steal pipes surrounded by small fins in which water flow for heating purpose .and these fins are used for heat transfer and cooling of pipes,
These modules are a type of heat exchanger where heat exchange takes place b/w DM water & exhaust of turbine.
Boiler drums are made by mild steel . because of its ductility.
3.7 SPECIFICATIONS OF BOILER DRUMS
1. HP DRUM : Design pressure Working pressure Hydraulic pressure Water temperature Holding time HP steam Steam temp 105kg/ cm2 78.2kg/ cm2. 157.5kg/ cm2 ambient 10 min. 79.8kg/cm2 490c
2. LP DRUM: Design pressure Working pressure Hydraulic pressure Water temp. Holding time Steam temp. 12kg/ cm2. 05 kg/ cm2 18kg/ cm2 ambient 10 min. 220c
3. CHIMENY EXHAUST: Maximum temperature Working temperature 90c 65-70c
CHAPTER-4
STEAM TURBINE (ST) & CONDESER

4.1 STEAM TURBINE
In a steam turbine steam is passed through nozzles or fixed blades where the heat drops takes place increasing the velocity of steam. the high velocity steam impinges on the curved vanes which causes the directions of the steam to be changed. Due to this change of momentum motive force is exerted on the moving blades and power is obtained.
4.2 ADVANTAGE OF STEAM TURBINE
1. the thermodynamic efficiency of steam turbine is higher than that of steam engine because these work on Rankine cycle whereas steam engine works on modified Rankine cycle. A steam turbine can thus take advantage of expansion up to the lowest pressre. the lowest exhaust pressure of steam turbine is as low as 2.5cm hg(.035 bar)whereas in steam engines it is 15 to 20cm of hg(.2to.3bar)
2. the mechanism is simple as inter mediate links like piston, piston rods, croos head, etc, are absent.
3. there is no initial condensation as the parts are subjected to constant temp. and at constant loads.
4. power is generated uniform rate ,hence no fly wheel is necessary.

5. no internal lubricant is necessary, which reduce the cost of lubrication and supplies a purer feed to the boiler.
6. due to absence of reciprocating parts, perfect balance is possible which avoids heavy foundations.
7. steam turbine can carry considerable overloads with only a slight reduction in efficiency.
8. the thermal efficiency of steam turbines plants is 35to40%, whereas for steam engine it is 15to 20 %.
LOSES IN STEAM TURBINE
1. Loss in the exit velocity of steam: The loss in the exit velocity of the steams due to blade efficiency not being 100percent.this is because of the obliquity of nozzles. if the nozzle angle is zero, blade efficiency would be 100 percent.
2. Loss due to friction and turbulence: Friction occurs in nozzles and blades and b/w steam and rotating disc. also due to centrifugal action steam is thrown radially towards the casing and dragged along the surface by the moving blades. these losses are called the disc friction and wind edge losses.
3.
Loss due to leakage: In impulse turbine leakage occurs b/w the shaft and the stationary diaphragms carrying nozzles. in the reactions turbine the leakage is at the blade tips.
4. Losses due to mechanical friction to the bearing , etc. this loss is less then 1 % and it decreases with the size of the plant.
5. Losses due to radiation is negligible.
6. Governer losses: it is due to throttling. This may in order to 5to10%.
7. Exhaust losses: the steam leaves the turbine with a finite. Absolute velocity which is partially or wholly lost.
In this plant steam turbine produces 110MW electricity, running by combined steam of HRSG. so in this plant cost of coal handling and ash handling is negligible.
4.3 WORKING OF STEAM TURBINE
The steam turbine is a Siemens Westinghouse KN Turbine Generator, capable of producing up to 240 MW. It is located on top of the condenser, across from the cooling tower.
Steam enters the turbine with temperatures as high as 1000 degrees Fahrenheit 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 generator, producing additional electricity, about 100 megawatts per HRSG unit.
After the steam is spent in the turbine process, the residual steam leaves the turbine at low pressure and low heat, about 100 degrees. This exhaust steam passes into a condenser, to be turned back into water.
39 | P a g e
By using this combined-cycle process, two gas turbines and one steam turbine,
we can produce a total of about 110 megawatts of electricity.
4.4 CONDESER
The purpose of the condenser is to turn low energy steam back into pure water for use in the Heat Recovery Steam Generator A condenser makes it possible to remove exhaust economically at a pressure less then that of atmosphere . thus by use of an condenser in a steam plant low exhaust pressure can be used and large heat drop per kg of steam utilized increasing both the efficiency and power output of the plant.
ADVANTAGE:
Hot feed water at 40c to 50c is available for returning to the boiler. Air and non condensable gases , which have corrosive action, are removed. Recovery of condensate reduce the make up water that must be added to the system. Where the feed water available is not pure , recovery of condensate reduce the capital and running cost of the water softening plant.
In a condenser , absolute vacuum is neither possible nor economical to maintain . beside enormous increases in the condenser size a higher vacuum result in lower temperature of the condensate returned to the boiler and increase in the rate of flow of cooling water and consequently the power required to derive the circulating pumps.
4.5 ELEMENT OF A CONDENSING PLANT
1. The condenser where steam is condensed. 2. The condensate pump for extracting water for the condenser to the hot well. 3. The hot well for collecting the condensate. 4. The air ejector or dry air pump for removing the non condensable gases from the condenser. 5. The circulating water pump for circulating the cooling water. 6. The cooling tower if same circulating water is to be used again and again. sometime the term hot well is applied to the collection space at the bottom of condenser and the hot well is termed surge tank
CHAPTER-5 COMBINED CYCLE POWER GENERATION
5.1 COMBINED CYCLE ELECTRICITY GENERATION
Growth in gas fueled combined cycle system will take place, Because of the attractive economic environmental and operating characteristics of this natural gas system . Combined cycle gas turbine plants generate electricity more. Efficiently than conventional fossil to percent compares with 30 to 50 percent for typical now biological units.
5.2 Advantage of Combined Cycle Gas Power Plant

High Thermal Efficiency Low water Requirement Environmental friendliness Fast start-up Low Gestation period Low Installation Cost
Disadvantage of Combined Cycle Gas Power Plant

Low thermal Efficiency in Open cycle Higher Cost of Generation Higher Maintenance Cost
5.3 Classification of Combined Cycle Gas Power Plant
SIZE SMALL MEDIUM LARGE
PLANT CAPACITY UP-TO 100 MW 150-400 MW > 400 MW
GT CAPACITY 30-40 MW 60-120 MW > 120 MW
5.4 Environmental effects of combined cycle electricity generation
(a). Natural-gas fueled combined cycle units are environmentally performable to conventional coal system the gas combined cycle unit produces none of the solid waste associated with coal units less than 1 percent of the sulfur dioxide and particulate matter and about 85 percent less nitrogen oxide produces by a similarity sized new coal unit equipped with pollution control equipments.
(b). Cogeneration System :- Cogeneration is use of a primary energy like natural gas to sequentially produce heat and electricity. The concept is based on the recover and use of waste heat produced daring the generation of electricity. In most electric utility power plants. This waste heat is lost resulting in substantially lower operating efficiencies than with cogeneration.
A variety of natural gas cogeneration technologies are currently being used. Including small prepackaged units that incorporate all the necessary components for a cogeneration system as well as high efficiency industrial gas turbines. These natural gas cogeneration system are available in sizes ranging from as small as 202 kw to as larges as several hundred mega watts.
(c.) Air Emissions :- The average emissions rates in the united states from natural gas fired generation are 1135 ibd/meh of carbon dioxide 0.1 ibs/mwh of sulfer dioxide and 1.7 ibs/mwh of nitrogen oxide compared to the average air emissions from coal fired generation natural gas produces as much carbon dioxide less than a third as much nitrogen dioxide at the power plant in addition the process of extraction treatment and transport of the natural gas to the power plant generators additional emissions.
(d) Design Principle :- in a gas turbine set composed primarily of a compressor burner and the gas turbine proper. The input temperature to the gas turbine is relatively high but the output temp of the fuel gas temperature is sufficient for production of steam in the second steam cycle with live steam temperature in the range of steam cycle depends on the ambient temperature and the methods of waste heat disposal either by direct cooling by lake river or sea water or using cooling towers.
(e) Efficiency of CCGT Plants :- The thurmel efficiency of a combined cycle power plant is normally in termsof the net power output of the plant as a percentage fo the lower heating value or net calorific value of the fuel. In the case of generating only etc. criticity power plant efficiencies of up to 59% can be achieved in the case of combined heat and power generation the efficiency can increase to about 85%.
5.5 WORKING OF A COMBINED CYCLE POWER PLANT
DCCPP located at Dholpur has an unique feature that the same energy source (i.e. natural gas) is used to rotate both gas and steam turbine without wasting much of energy. As the name implies it is a combined cycle i.e. waste heat from the gas turbine is recovered by a heat recovery steam generator to power a conventional steam turbine in a combined cycle configuration.
5.5.1 Power Generation: 1) Air Inlet

The amount of air needed for combustion is 800,000 cubic feet per minute. This air is drawn though the large air inlet section where it is cleaned, cooled and controlled, in order to reduce noise.
2) Two Siemens Westinghouse 501FD Turbine-Generators:

The air then enters the gas turbine where it is compressed, mixed with natural gas and ignited, which causes it to expand. The pressure created from the expansion spins the turbine blades, which are attached to a shaft and a generator, creating electricity. Each gas turbine produces 185 megawatts (MW) of electricity. The blades are attached to a rotor, which spins the generator, and makes electricity. Think of a generator as a huge spinning magnet inside a coil of wire. As the magnet spins, electricity is created in the wire loops.
3) Heat Recovery Steam Generator (HRSG)

The hot exhaust gas exits the turbine at about 1100 degrees Fahrenheit and then passes through the Nooter Erickson, Heat Recovery Steam Generator (HRSG). In the HRSG, there are 18 layers of 100-foot tall tube bundles, filled with high purity water. The hot 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 much cooler 180 degrees, after having given up most of its heat to the steam process. About 1 million pounds of steam per hour is generated in this way and sent over to the steam turbine through overhead piping.
4) Steam Turbine
The steam turbine is a Siemens Westinghouse KN Turbine Generator, capable of producing up to 240 MW. It is located on top of the condenser, across from the cooling tower. Steam enters the turbine with temperatures as high as 1000 degrees Fahrenheit 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 generator, producing additional electricity, about 100 megawatts per HRSG unit. After the steam is spent in the turbine process, the residual steam leaves the turbine at low pressure and low heat, about 100 degrees. This exhaust steam passes into a condenser, to be turned back into water. By using this combined-cycle process, two gas turbines and one steam turbine, we can produce a total of about 110 megawatts of electricity.
5.5.2 Emissions Control
1) Selective Catalytic Reduction (SCR)
To control the emissions in the exhaust gas so that it remains 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) emissions.
2) 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.
3) Best Available Control Technology (BACT)
Our annual average concentration of NOx is only 2 parts per million, which is considered 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 analyzed, assuring that permit limits are being met. With this kind of clean, modern technology, the exhaust stack is only 145 feet high, compared to 500 feet, the height required by older power plants that use less efficient emission technology.
Environmental and health organizations recognize this technology as a benefit to the community. The local chapters of the American Lung Association and Sierra Club both support the Metcalf Energy Center.
5.5.3 Transmission of Generated Power onto the Grid
1) Transformers
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 sends power to the substation. A small amount of generation is directed to Auxiliary 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 Energy Center requires 12 15 megawatts to operate.
2) Switchyard
From each transformer, the power passes underground into our switchyard. The power from all of the generators comes together there, where it is measured, metered and directed onto the grid.
The proximity of the site to a large, existing PG&E substation makes it a good place to build a power plant and the nearest transmission tower is only about 200 feet away.
3) Condenser and Cooling Tower
The purpose of 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 circulating water that passes through the condenser. It consists of ten cells with large fans 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 basin, hot wet air goes out of the stacks. Normally, hot moist air mixes with cooler 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 Commission considered this visually undesirable in this community so we added a Plume-Abatement feature, louvers along the topsides of the tower that control the air flow.
The cooling tower evaporates about three-fourths of the processed, recycled water, then we send about one-fourth of it back through the sewer lines for retreatment by the City.
The Metcalf Energy Center purchases 3 to 4 million gallons per day of recycled water from the City of San Jose. Evaporation of this water assists the City in adhering to their flow cap limits and helps to protect the sensitive saltwater marsh habitat of the San Francisco Bay environment from receiving too much fresh, recycled water.
5.6 Water Tanks, Natural Gas Pipeline, Control Room
1) Water Tanks
The largest tank is the Service Water tank. It contains 470,000 gallons of water to be used for drinking, fire fighting and for the high purity water train. The water from the service water tank is pumped to the water treatment building where it then passes through a reverse osmosis unit, a membrane decarbonater, and mixed resin bed demineralizers 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.
2) 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 the east of our site. During construction, Horizontal Directional Drilling was utilized with careful coordination with many local authorities. The pipeline was built 60 feet
underground and passed under highways, creek, train tracks, and environmentally sensitive areas. The pipeline enters the site just behind the water tanks, where equipment regulates 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, pressure and purity.
3) Control Room
From the control room, the plant operators monitor and operate the facility, via the plants Distributed Control System, with the click of a mouse, viewing graphic representations of all MEC systems on various screens. 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.
CONTROL ROOM
WATER TANK
CHAPTER-6
WATER CLARIFICATOIN CUM FILTRATION PLANT & TURBO-GENERATOR AND EXCITATION SYSTEM
6.1 WATER CLARIFICATOIN CUM FILTRATION PLANT
The source of water to the power station is from across river Chambal .the total water requirement for the capacity 330 MW is estimated at 850 cusses . the river water contains different impurities Suspended Impurities Removed by Al, Cl2 , Co(OH) 2 where alum is used to coagulate. Colloidal Impurities Removed by alum and filteration of water Soluble impuritiesBiological Impurities-
6.1.1 VARIOUS PROCESS THAT ARE INVOLVED IN TREATMENT OF WATER:
1. Coagulation with chemical addition in slash mixture. 2. Filteration in rapid gravity filter 3. Chlorinisation for removal of organic matter. 4. Clarification in clariflocculator.
The coagulated particles are removed in form of sledge. filteration plant consisting of rapid gravity filters supplies filtered water for dm plant. Raw water is pumped by means of pumps located in CW pump house and enters the clariflocculator through a raw water
inlet channel and flash mixer. Alum, lime and chlorine solution are dosed in raw water channel and mixed with it. A tap of is taken from the clarified water channel to five rapid sand filter of capacity(60 m3/hr each). Now it is purified to dm water requirement of all the 4 units. M?S Geo Miller & Co. Pvt. Ltd. Supplies equipment for this plant
6.1.2 DEMINERALIZING PLANT
Purified water coming from classifier is sent to dm plant through pumps. Impure water causes sludge and scale formation inside the boiler hence the need of dematerialized water arises. The water in dm plant undergoes through various steps.
1. ACTIVATED CARBO FILTER (ACF):

Tank in which alternate layers of CO2 and sand are placed. Ac waterfalls from top, suspend particles (not removed by classifier) are filter. Also the excess of chlorine is removed from here water goes into SAC tank.
2. STRONG ACID CATION TANK (SAC TANK):

This tank has 2 layers of resins which is used to remove cautions or positive ions viz. Ca2+, Mg2+, Fe2+, K+. (R) H + CaSO4 -----> R- Ca + H2SO4/H2CO3/HCO3/HCL Resin is a polymer of PVC. It contains polystyrene and polyvinylchloride. From SAC tank, water is pumped to degassifire.
6.1.3 DEGASSIFIRE
In it oxygen is removed from the water to avoid corrosion at later stages water falls from the top and air at high pressure is passed as a jet through it in a partially evacuated chamber like vessel. This take away the oxygen from water. Now the water is pumped to WVA tank. It improves pH of the water.
6.1.4 WEAK BASE ANION TANK
In this tank, the negative anions are removed from minerals by the reaction (R) OH + H2SO4 -----> H-OH + RSO4 The R SO4 part is filtered through resin layer used. The filtered from above process is free from trivalent ions and most of the bivalent ions. Bivalent ions left and the monovalent ions are removed in SBA tank.
6.1.5 POLISHINGING UNIT
It consists of tank which have mixed bed (layers, which have the ability remove positive as well as negative ions). The water emerging out of this unit is dm water.
6.1.6 DM WATER QUALITY

pH Iron, free CO2 Conductivity Total silica Total electrolyte between 6 to 8 not traceable less than 0.3 micro siemons / cm at 20c less than .020 PPM less than 0.1 PPM
After both the anion and cation exchanger get exhausted, anion exchanger is then treated with NaOH and cation exchanger is then treated with H2SO4
6.1.7 WATER SOFTNER

water softening plant also known as zeolite water softening plant has been provided to meet bearing cooling water and make up water loss.
6.1.8 ANALYZER DM PLANT

Analyzer is an instrument, which is used for the monitor the situation of water at various points . analyzer is an instrument because it 1. Gives an inside picture of the process and avoid shut down of machine. 2. it prevent the change in boiler , tubes , turbine blades and generator. 3. SiO2, Na , dissolved O2 ,NH3 Are monitored when the quantity is exceeding by a limit.
THE MONITORING POINTS ARE

1. HPH to economizer - O2 2. at boiler - SiO2 , Cl 3. Condenser to extraction pump 4. Water treatment plant to condenser (Na , SiO2)
SPECIFICATIONS OF CW PUMPS
Power Rated capacity Rated speed No load current Full load current Direction of rotation Voltage 1700KW 16000m3/hr each 497rpm 81 amp 193.7 amp Clock wise from top 6.6KV
6.1.9 CW PUMP HOUSE
The cooling water for condenser should be drawn from intake sump through CW pump. At the entrance of each CW pump, there exists a seal pit from intake sump, traveling water screens are provided for efficient screening of cooling water and preventing devris from going into cooling system The hot water from each unit condenser is connected to seal pit. The CW pipe work is provided with necessary butterfly valves and rubber expansion joints at require points.
6.1.10 WATER CLARIFIER
It is provide for removing turbidity. Suspended and colloidal solids from raw water by chemical treatment. All pipe works, storage tanks chemical dosing equipments are designed to meet the requirements. The raw from chambal river will be taken into the outdoor CW sumps through CW intake channel. To collect water in this sump will be pumped to clarification and filteration plants. Through vertical turbine raw water pumps located in the pump house. The raw water pumps located in the pump house.
6.2 TURBO-GENERATOR AND EXCITATION SYSTEM
An Turbogenerator is an electromechanical device that converts mechanical energy to electrical energy, using a rotating magnetic field
6.2.1 THEORY BEHIND THE WORKING OF A TURBOGENERATOR
An Turbogenerator generally includes a rotor that rotates within a stator core to convert mechanical energy into electrical energy.
A frame-supported stator core provides a high permeability path for magnetic flux and a rotor assembly positioned to rotate continuously within the stator core so as to induce electrical current.
The resulting current is carried by high-current conductors through and out from the power generator, to connectors that provide the current to a plant bus for power distribution.
6.2.2 Main Components of Generator
Stator Stator Frame (Fabrication & Machining)
Core Assembly Stator Core, Core Suspension Arrangement
End Shield Stator Winding Assembly Stator Winding , Winding Assembly, Connecting Bus bar, Terminal Bushing
Rotor Exciter Auxiliary Systems Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor, Rotor Assembly
Completing Assembly Bearing Assembly, Shaft Seal Assembly, Oil Catchers, Insert Cover etc
6.2.3 FUNCTIONS OF EXCITATION SYSTEM
GENERATION OF AIR GAP FLUX TO GET ELECTRICAL OUTPUT. TO GENERATE SYNCHRONISING TORQUE TO KEEP THE MACHINE IN SYNCHRONISM. TO GENERATE REACTIVE POWER (MVAR) FAST RESPONSE TO SYSTEM DISTURBANCES. CAPABILITY TO GENERATE FIELD FORCING CONDITION FOR PROMPT CLEARANCE OF FAULTS.
6.2.4 BRUSHLESS EXCITATION SYSTEM
CONTACT LESS SYSTEM ELIMINATES ALL PROBLEM RELATED TO TRANSFER OF POWER BETWEEN STATIONARY AND ROTATING ELEMENTS COMPLETELY ELIMINATES BRUSHGEAR , SLIPRINGS, FIELD BREAKER . ELIMINATES THE HAZARD OF CHANGING BRUSHES ON LOAD BRUSH LOSSES ARE ELIMINATED RELIABILITY IS BETTER IDEALLY SUITED FOR LARGE SETS
CHAPTER-7 220KV SWITCH YARD & TRANSFORMER AND MAINTENANCE WORK

7.1 220KV SWITCH YARD 7.1.1 BUS SCHEME
Main Function Of The Stations Is To Receive The Energy And Transmit It At The Required Voltage Level With The Facility Of Switching. At STPS Following Are The Bays:1 2 3 4 5 6 7 8 9 Bus Coupler - 1 Sog -1 Sog -2 Generator Transformer -1 Ratangarh -1 Station Transformer -1 Bus Sectionalizer Ratangarh - 2 Bus Tie
10 Generator Transformer-2 11 Interlinking-1 12 Station Transformer-2 13 Interlinking -2 14 Station Transformer-3 15 Station Transformer-4 16 Station Transformer-5
7.1.2 Bus System There Are Mainly Three Buses 1 2 3 Main Bus-1 Main Bus-2 Transfer Bus
Material of bus bar- Tarantull Al conductor with a capacity of 2400 amperes. Bus coupler-1 can be used as GT breaker for unit 1, 2 and 3. Only one bus coupler can be used as a GT breaker at a time.
7.1.3 SF6 GAS CIRCUIT BREAKERS:
In this type of breaker quenching of arc is done by SF6 gas. The opening and closing of the circuit breaker is done by air.
TYPE DESIGNATION:E L F SL 4 1 : : : : : : S F 6 Gas Insulation Generation Out Door Design Breaker Construction Code BIL Rated Voltage 4 - 245 / 460 / 1050 kv No. of chamber
The high voltage circuit breaker type ELF SL 4-1 comprises 3 breaker poles , a common control cubicle and a pneumatic unit ( compressed air plant)
A breaker pole consists of :- SUPPORT (FRAME) - POLE COLUMN - PNEUMATIC ACTUATOR ( PKA) 40000 41309 N 90200
The actuator is operated with compressed air. A pneumatic unit ( 97200), an air receiver and a unit compressor is installed to supply the compressed air. the compressed air stored in the air receiver is distributor to the three actuator via pipe line.
The common control cubicle ( 96000), which is installed separately contains all control devices and most of the monitoring instrumentation with the exception of the density monitor 98005 mounted on the middle breaker pole. the pressure switches are installed in the control cubicle. all three poles columns are filled with insulating gas and interconnected by means of pipe lines. the gas is monitored by a density monitor 98005 ( temp. compensated pressure monitor )
If all the poles of the circuit breaker do not close simultaneously then the pole discrepancy relay will operate and trip the breaker. Also at the time of tripping, if all the breake rs do not trip simultaneously, then again the tripping command through the pole discrepancy relay will initiate to trip the breaker and annunciation will appear in the sub station control room and the UCB.
7.1.4 ISOLATORS:
Isolators are used to make or break the circuit on no load. They should never be operated on load. The isolators installed in the sub station have a capacity of 1250 amperes. They are double end break type, motor operated and can be operated from local as well as remote. 7.2 TRANSFORMERS 7.2.1 CURRENT AND CAPACTIVE VOLTAGE TRANSFORMERS: These are used for metering and protection. It should always be kept in mind that a CT should never be open circuited and a PT should never be short-circuited.
7.2.2 LIGHTINING ARRESTOR AND ARC HORNS: Protection against lighting.
7.2.3 CHANGE OVER SCHEMES (BUS TIE SYSTEM): When main breaker is in service (on load change over): 1 2 3 4 5 6 7 Ensure Transfer bus is free (check any temporary earthing) Charge the transfer by closing bus coupler isolator and circuit breaker. Put the switches provided on bus coupler on generator control cum desk panel. Charge the transfer bus by closing isolator d of GT. Check the isolator of GT through which it has been already connected to the bus. Close the isolator e,f, & g of tie Bus. By using synchronizing trolley close the circuit breaker b1
BUS COUPLER TO MAIN BREAKER o Close the isolator 1 & 3 of GT. o Close the breaker a 1 of GT o Close the isolator 5,7 & breaker b 1 o After this work close the isolator 9, 10 o By using synchronizing Troley, close the bus coupler breaker c1
7.2.4 SYNCHRONIZATION OF THE GENERATOR TO THE GRID (Generator breaker is used)
With The Main Bus: 1. Close the isolator with the bus selection 2. Close the isolator on both sides of the generator breaker. 3. On Generator control desk panel(GCDP) a. Put the switch NIT in normal position. b. Put the synchroscope ON. c. Measure the voltage and speed matching. Conditions will be included by checking the synchronizing lamp on GCDP and close the generator breaker.
IMPORTANCE OF THE TRANSFER BUS
Transfer bus is normally free and is used to facilitate repairing job of other breakers by transferring load on transfer bus
7.3MAINTENANCE JOBS TO BE DONE ON 220KV SWITCH YARD
7.3.1 Daily Job
Visual checking for any hot spot Checking of air leakage from the breaker Checking for any gas leakage from the breaker Checking of air pressure of breaker Checking of gas pressure of breaker Checking of oil leakage form CT and CVT Checking of oil level from CT and CVT Checking of lubricating oil level in compressors Checking healthiness of trip circuit for all breakers.
7.3.2. Monthly Job
Thermo vision scanning of conductor joints and attending to the hot spot on available opportunity Breaker operation checking from local and remote Isolators operation from remote and local. Measurement of specific gravity and voltage of 220 V D. C> Battery cells.
7.3.3. Quarterly Job
1) Breakers
1. Tightening of breaker clamps 2. Cleaning of breaker cubicles 3. Checking of oil level of compressors of SF6 breakers. 4. Lubrication of rollers, mechanism shafts, anti pumping pin and c clips. 5. Checking operation of breakers through trip coil 1, trip coil 2, both the coils, anti pumping operation and pole discrepancy operation 6. Checking of pressure of gas and air pressure of breakers.
2) Isolators
1. Tightening of the jumper clamps 2. Tightening of electrical connections 3. Cleaning of male female connections 4. Checking of fuses and replacement there F. 5. Checking of operation of isolators
3) Current transformers
1. Checking of oil level. 2. Checking of oil and leakage 3. Tightening of jumper clamps 4. Tightening of electrical terminal secondary connection
4) Lightning Arrestors
1. Tightening of jumper connections 2. Tightening of earthing connections 3. Checking of counter reading 4. Checking of porcelain part 5. Checking of grading current
5) Capacitive Voltage Transformer
1. Checking of oil level and leakage 2. Tightening of HT jumper clamps. 3. Tightening of secondary terminal connections
6) Battery 220 V D. C.
1. Cleaning of battery terminals 2. Tightening of battery terminal connections 3. Recording of specific gravity and voltage of each cell.
7.3.4 DURING ANNUAL SHUT DOWN OF UNITS
1) Breakers
1. Checking and cleaning of porcelain part of the breaker. 2. Tightening of breaker clamps. 3. Cleaning of breaker cubical 4. Tightening of all the terminal connection 5. Lubrication of I) C and D Roller (II) Locking pins (III) Anti Pumping pins (IV) Mechanism Shafts 6. Recording of closing and tripping of each phase 7. Recording of insulation resistance value of breaker 8. Checking of annunciator and inter locks. a. Air pressure low b. Air pressure very low trip circuit cut off c. Gas pressure low d. Gas pressure trip circuit off and other ann. of breaker 9. Checking of tripping through a. Trip Coil I b. Trip Coil II c. Through both the trip coils d. Anti Pumping operation e. Pole Discrepancy operation 10. Measurement of resistance of trip cells and closing coils 11. Checking of air leakage and its stoppage
12. Checking the gas leakage 13. Replacing the oil of compressors 14. Checking of auto operation of compressors 15. Complete maintenance of compressors 16. Checking of closing/tripping of breaker from local remote
2) Isolators 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cleaning of male female connections Tightening of all the jumper clamps Lubrication of control rotary post insulator with grease Checking of proper operation of the isolator Tightening of all the nuts and bolts Cleaning the motor cubical Tightening of all the terminal connections Greasing the gear box of motor Checking of all the fuses Checking of operation of isolator from local/remote
3) Current Transformers 1. Checking / cleaning of porcelain part of CT 2. Checking of oil and level and stopping it if low 3. Checking of oil leakage and its stoppage 4. Checking of N2 pressure and maintaining it at 0.2 kg/cm2 5. Tightening of earthing connection 6. Checking of BDV value of CT oil 7. Tightening of all the secondary terminal connections 8. Cleaning of marshalling box and tightening of terminal connections 9. Recording of IR values of primary and secondary side of CT 10. Tightening of bushing clamps.
4) Capacitive Voltage Transformers
1. Checking of oil level and topping thereof 2. Checking of N2 pressure and maintaining it at 0.2 kg/cm2 3. tightening of jumper clamps. 4. Tightening of secondary connection 5. Recording of IR values of primary and secondary side 6. BD value of oil
5) Lightning Arrestors
1. Cleaning of porcelain part and checking 2. Tightening of earthing connection 3. Tightening of jumper connection 4. Recording of IR values 5. Checking of counter readings 6. Checking of grading current
CHAPTER-8 DC SYSYTEM & POWER LINE CARRIER COMMUNICATION

8.1 DC SYSTEM
8.1.1 BATTERIES
Main Building Wet cell battery bank o 125 V Battery Bank 1 o 125 V Battery Bank 2 o 125 V Battery Bank 3 o 125 V Battery Bank 4 o 220 V Battery Bank 1 o 220 V Battery Bank 2
Dry cell battery o Battery Bank
8.1.2 SWITCHYARD BUILDING BATTERY BANK 220 V Battery Bank 1 220 V Battery Bank 2 48 V Battery Bank 1 48 V Battery Bank 2
8.1.3 BATTERY ROOM Battery room should be well ventilated, clean, dry and temperature moderate (Damping is dangerous due to possibility of earth leakage from the battery) Smoking is prohibited
Battery get best result at the room temperature between 20 35o C
8.1.4 ELECTROLYTE It is a mixture of Acid and Pure Water (Distilled) with proper portion. General value of proportion is 85 % water and 15 % acid. Gravity to be maintained 1.200 + 0.005 in al the cells.
CAUTION Batteries and Battery Room should be clean, dry and well ventilated. Never allow a flame, cigarette near the batteries. Wear old clothes or terylene when working with acid or electrolyte (Terylene is resistant to dilute acid). Never add water to acid. It will spurt dangerously
8.1.5 TEMPERATURE CORRECTION The specific gravity of the electrolyte works with temperatire. Any reading observed on the hydrometer should therefore be corredted to 270o C as all the specific gravity values indicated by use are at 27o C For every 1o C above 27o C add 0.007 to the specific gravity as read on hydrometer
8.1.6 NORMAL OPERATION OF BATTERIES Keep the battery on trickle charge continuously (25 hrs. each day) except where it is on discharge or on Boost charge. The trickle charge current shown on milli ammeter should be so adjusted that the battery be kept fully charges without being over charged. The trickle charging current should be so appropriate that it should neither be too much trickle charge not too little trickle charge. The value above 2.3 and below 2.25 volts per cell during routine checking it found means adjustment of trickle charging current is required.
8.2 POWER LINE CARRIER COMMUNICATION

8.2.1 EARTH SHIELDING
It is a mesh of wire upon the tower. Its main purpose is to protect the substation equipment from direct lightning strokes. Metallic body of each equipment is properly earthed. The earthing resistance of any switch yard is about 0.2 ohm. Before the building up of the sub station earthing material of G. I. wire is buried in the ground whose depth depends upon the moisture content of ground. Earthing electrodes are provided at various points. This increases the number of parallel provided at various points. This increases the number of parallel paths and hence resistance of earth decreases.
This is a technique in which power lines are used as communication lines by which we can make contact with other substation
The range of frequency used for communication is 300 KHz to 500 kHz.
8.2.2 WORKING
The voice frequency if converted into electrical signal. These signals are super imposed on a carrier frequency and transmitted on the line through a coupling capacitor. At the receiving end wave trap does not allow the modulated signal to enter the power circuit where as the coupling capacitor provides a low resistance path to this signal. This signal is then given to the line matching unit. In the LMU this frequency is matched and after wards filtration of signal is done. The signal is demodulated and again converted into the voice signal, which is available at phone receiver.
RESULT AND CONCLUSION

The Summer Training completed in Dholpur Combined Cycle Power Project (DCCPP) during the period 25th May 09 to 17th July 09 is successful in all respects. There I studied Gas Turbine, Steam Turbine, Boilers and all equipments that are use for generating the electricity. On doing Summer Training there I came to know that DCCPP project is under the RVUNL (Rajasthan Rajya Vidhyut Utpadan Nigam Ltd.) and Its capacity is 330MW.
It has been a wonderful experience for me for working in DCCPP as a Trainee and if given chance I would like to be a part of this Organisation.
BIBLIOGRAPHY
rvunl.com google.co.in wikipedia.org Own Experience

Summer Project Report (Prakhar Gupta, A2305106167)

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Summer Project Report (Prakhar Gupta, A2305106167)

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DCC

Supervisor: Mr. H.P. SINGH Mrs. EILA SHARMA

Submitted By: Mr. PRAKHAR GUPTA B.Tech ECE ,21008

Mr. H.P. SINGH

Mrs. EILA SHARMA

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5.6 Water Tanks, Natural Gas Pipeline & Control Room 50

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8.1.6 Normal operation of Batteries

RESULT AND CONCLUSION

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CHAPTER-1 INTRODUCTION OF THE ORGANISATION

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1.3 SELECTION OF SITES FOR THE GAS POWER PLANT

6. DISTANCE FROM THE POPULATED AREA

Climate conditions of a place play a significant part in economics of capital investment.

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1.4 FEATURES OF THE PLANT

TECHNICAL DATA: 1. COST OF THE PLANT Rs. 1155.15 Crore (STAGE-1)

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3. CHIMNEY HEIGHT Unit: 1, 2 220 Mt

4. WATER REQUIREMENT 400 m / hr (3 x 110m.w.)

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BOILER Type Capacity Make Steam Temperature Steam Pressure

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1.5 PLANT LAY OUT

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CHAPTER-2 GAS TURBINE (GT)

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2.1 WORKING OF GAS TURBINE

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2.2 THEORY OF OPERATION

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2.2.1 Gas Power Cycle

2.2.2 Bray ton Cycle:-

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CHAPTER-3 HEAT RECOVARY STEAM GENERATOR (HRSG)

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3.2 APPLICATIONS OF HRSG

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3.3 COMPONENT & ARRANGEMENT OF HRSG

There are two boiler drums in HRSG-

There are three main components of HRSG 1.Economisers 2.superheaters 3.evoporator

The advantage of economizer are

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3.4 SALIENT FEATURES OF HRSG

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3.5 ARRANGEMENT OF HRSG DCCPP PLANT

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3.6 WORKING OF HRSG

2. DATE OF SYNCHRONIZATION: UNIT 1 1sep2007UNIT 2 1sep2007UNIT 3 1 Jan 2008 __