"A Study of Siddhirganj 2120 MW Peaking Power Plant of EGCB"
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"A Study of Siddhirganj 2120 MW Peaking Power Plant of EGCB"
ELECTRICITY GENERATION COMPANY OF BANGLADESH ELECTRICITY GENERATION COMPANY OF BANGLADESH ELECTRICITY GENERATION COMPANY OF BANGLADESH ELECTRICITY GENERATION COMPANY OF BANGLADESH
Submitted To Submitted To Submitted To Submitted To Engr. Md. Abul Bashar Course Coordinator Department of Electrical and Electronic Engineering IUBATInternational University of Business Agriculture and Technology
Submitted Submitted Submitted Submitted By By By By Faujul Kabir ID # 10105132 Program: BSEEE
Date of Submission Date of Submission Date of Submission Date of Submission : 10 th August, 2014
IUBAT IUBAT IUBAT IUBAT INTERNATIONAL UNIVERSITY OF BUSINESS INTERNATIONAL UNIVERSITY OF BUSINESS INTERNATIONAL UNIVERSITY OF BUSINESS INTERNATIONAL UNIVERSITY OF BUSINESS AGRICULTURE AND TECHNOLOGY AGRICULTURE AND TECHNOLOGY AGRICULTURE AND TECHNOLOGY AGRICULTURE AND TECHNOLOGY
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10 th August, 2014
Engr. Md. Abul Bashar Faculty and Course Coordinator Department of Electrical and Electronic Engineering IUBAT- International University of Business Agriculture and Technology 4, Embankment Drive Road, Uttara Model Town, Sector 10, Dhaka 1230, Bangladesh.
Subject: Submission of practicum report.
Dear Sir
With due respect, I like to submit this report as partial fulfillment of the BSEEE program, the topic named "A study of Siddhirganj 2120 MW Peaking Power Plant of EGCB". It was superlative opportunity for me to work on this topic to actualize my theoretical knowledge in the practical area and to have an enormous experience in power plant operation, maintenance and protection. Now I am looking forward for your kind assessment regarding this report.
I would be very kind of you, if you please have a look on this report and evaluate my performance regarding this report.
Yours Sincerely
_________________ Faujul Kabir ID # 10105132 Program: BSEEE
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Letter of Transmittal
10 th August, 2014
Engr. Md. Abul Bashar Faculty and Course Coordinator Department of Electrical and Electronic Engineering IUBAT- International University of Business Agriculture and Technology 4, Embankment Drive Road, Uttara Model Town, Sector 10, Dhaka 1230, Bangladesh.
Subject: Letter of Transmittal.
Dear Sir
With due respect, I want to draw your kind attention that I am a student of Bachelor of Science in Electrical and Electronic Engineering (BSEEE). For completion of my graduation I have done my practicum in Siddhirganj 2120 MW Peaking Power Plant and have prepared this report titled as "A study of Siddhirganj 2120 MW Peaking Power Plant of EGCB".
I tried my level best to make the report ingenious by integrating the most complete information available and also by implementing my competency and learning. I hope this report will serve its best and the readers will come to know the operation of visual basic that may motivate them to work with this program. If any unwilling mistake has been found or anything need to be include or any clarification is needed please feel free to contact me.
Yours Sincerely
_______________ Faujul Kabir ID # 10105132 Program: BSEEE
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Training Certificate Training Certificate Training Certificate Training Certificate
I hereby declare that I have uniquely prepared this report which is entitled as "A study of Siddhirganj 2120 MW Peaking Power Plant of EGCB" after completion of two months practical work in Siddhirganj 2120 MW Peaking Power Plant, a power plant of Electricity Generation Company of Bangladesh.
I also confirm that the report is only prepared to fulfill the academic requirement and not for any other purpose. It will not be used with the interest of any other competitor.
____________________ Faujul Kabir ID # 10105132 Department of Electrical and Electronics Engineering IUBAT - International University of Business Agriculture and Technology
All praise is to the Supreme Being; creator and ruler of the universe, Almighty Allah, whose mercy keeps us alive and to pursue my education in Electrical and Electronics Engineering and to complete the Practicum Report. Also gratefulness to my parents by whose inspiration Im going to complete my graduation.
This Practicum Report which is entitled as "A study of Siddhirganj 2120 MW Peaking Power Plant of EGCB" in Siddhirganj 2120 MW Peaking Power Plant is the concrete effort of a number of people. In the process of conducting this report, I would like to express my gratitude and respect to some generous persons for their immense help and enormous cooperation.
First of all I would like to pay appreciation to Honorable Vice Chancellor Prof. Dr. M. Alimullah Miyan for giving me chance to prepare my research about this splendid topic.
I am very much grateful to my respected Course Coordinator Engr. Abul Bashar for his painstaking guidance and constant inspiration to do this report. I would like to thank my respected faculty Dr. Md. Azizul Huq for his guidance.
After that I would like to express my special gratitude to Engr. Md. Saiful Islam, Executive Engineer (Electrical) and Engr. Md. Aminul Haque Khan, Executive Engineer (Technical). I am very much grateful to my respected supervisor Engr. Abu Sayeed, Sub Divisional Engr. (Electrical), Engr. Md. Golum Mortuza Khan, Deputy Manager (Technical), Engr. Nandhipan Das, Sub Divisional Engr. (I&C) and Foreman Mr. Jibon for their diligent struggle for my practical experience and encourage me to do this work.
Finally I also feel it is important to acknowledge and thanks to my classmates, friends especially to those who appreciate me to do this internship program in a power plant.
Author
_______________ Faujul Kabir ID # 10105132 Program: BSEEE
This project paper provides a summary assessment of "A study of Siddhirganj 2120 MW Peaking Power Plant of EGCB".
In this report I have tried to focus on Gas Booster Compressor, Gas Turbine, Generator, Sub- station equipments, Switchgear & Protective Relays of 2120 MW gas turbine power plant in Siddhirganj. That means I have showed the overall power generating process of Siddhirganj 2120 MW Peaking Power Plant.
The main raw material of a gas turbine generator is natural gas. Natural gas goes through the gas turbine and works as a prime mover. The prime movers mechanical energy then goes through the alternator and its output is electrical energy. The power plant supply power to the national grid. Two generators provide 240 MW power in which each of rated voltage 11KV. After generation, The Voltage is stepped up to 132 KV using a power transformer because the national grid voltage is 132 KV.
Auxiliary transformers are used for internal supply. There is also one diesel generator to supply power when the plant blacks out. All the switchgear and protection devices are placed in safe area. The plant has the modern control system with Mark VI and it is controlled by experienced manpower. The power plant also has Central Control Room (CCR), Mechanical & Electrical Workshop and Instrumentation and Control (I&C) department. All the equipments of this power plant are functionalized by latest technology as well as each set up of instruments are well set by proper methods. If any faults occur, operation team informs the maintenance team for solving it and maintenance team helps them as quickly as possible.
During the period of my internship, I have learnt function of Gas Booster Compressor, Gas Turbine, Generator, Sub-station, Controlling System of all machinery, how power is being distributed to the national grid as well as various types of electrical equipment such as, AC motor, DC motor, Relay, magnetic contactor, sensor etc.
This report will satisfy the thirst of knowledge about how electricity produced that means the source of power, electrical machines and apparatus used in this plant for generating power. My effort will be successful if this report makes the analyzer understand the process how power is generated.
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Table of Content Preparatory Part Topics Page No. Title Fly I Title Page II Submission of practicum report III Letter of Transmittal IV Training Certificate V Student Declaration VI Acknowledgement VII Executive Summary VIII Table of Content IX List of Figures XV List of Tables XVIII
2.1 Background of EGCB Ltd 3 2.2 Board of Directors of EGCB Ltd. 3 2.3 Contact Address of EGCB Ltd. 3 2.4 Vision of EGCB Ltd. 4 2.5 Mission of EGCB Ltd. 4 2.6 Quality Policy 4 2.7 Core Value 4 2.8 Objectives 4 2.9 Strategies 5 2.10 Completed Project 5 2.11 Upcoming Project 5
CHAPTER 03 PLANT OVERVIEW Topics Page No.
3.1 Siddhirganj 2120 MW Peaking Power Plant Project 6 3.2 Siddhirganj 2120 MW Peaking Power Plant 7 3.3 Land Lease Agreement 7 3.4 Power Purchase Agreement 7 3.5 Model of Siddhirganj 2120 MW Peaking Power Plant 8 3.6 Single line diagram of Siddhirganj 2120 MW Peaking Power Plant 9 3.7 Organogram of Siddhirganj 2120 MW Peaking Power Plant 10 CHAPTER 04 GAS TURBINE Topics Page No. 4.1 General Details 11 4.2 Gas Turbine details in Siddhirganj 2120 MW Power Plant 11 Page | XI
4.3 Gas Turbine Functional Description 12 4.4 Gas Turbine Construction Features 13 4.3.1 Compressor 13 4.3.2 Combustion 16 4.3.3 Turbine 20 4.5 Exhaust Frame and Diffuser 26 CHAPTER 05 GAS TURBINE GENERATOR Topics Page No. 5.1 Generator 28 5.2 Generator Types 28 5.2.1 Rotating-armature Generators 28 5.2.2 Rotating-field Generators 29 5.3 Polyphase Generators 30 5.4 Generator Details of Siddhirganj 2120 MW Peaking Power Plant 31 5.5 Different parts of Generator 33 5.5.1 Stator 33 5.5.2 Rotor 34 5.5.3 Bearings 36 5.5.4 Coupling 36 5.6 Excitation System 36 5.6.1 Rectifier Wheels 36 5.6.2 Automatic Voltage Regulator (AVR) 37 5.6.3 Main Exciter 38 5.6.4 Pilot Exciter 38 5.7 Functional Description of Excitation System 38 5.8 Exciter Details of Siddhirganj 2120 MW Peaking Power Plant 39 5.9 Generator Protections 40 5.9.1 Over Current Protection 40 5.9.2 Over Voltage Protection 40 5.9.3 Frequency Protection 40 5.9.4 Frequency Relay 40 Page | XII
5.9.5 Rotor Earth Fault Protection 41 5.9.6 Under Excitation (Loss of field) Protection 41
CHAPTER 06 SUBSTATION AND SWITCHGEAR Topics Page No. 6.1 Substation 42 6.1.1 Substation Arrangement of Siddhirganj 2120 MW Power Plant 43 6.1.2 Substation Layout of Siddhirganj 2120 MW Power Plant 43 6.2 Elements of a Substation 44 6.3 Power Transformer 45 6.4 Mid Voltage Unit Auxiliary Transformer 46 6.5 Auxiliary Transformer 47 6.6 Instrument Transformer 48 6.6.1 Current Transformer 48 6.6.2 Potential Transformer 49 6.7 Transformer Protection 50 6.7.1 Differential Protection 50 6.7.2 Protective Relay 50 6.7.3 Over-current Relay 50 6.7.4 Distance Relay 50 6.7.5 Buchholz Relay 51 6.8 Lightning Arrester 52 6.9 Isolator 52 6.10 Switchgear 54 6.11 Circuit breaker 54 6.12 Circuit Breaker Used in Siddhirganj 2120 MW Peaking Power Plant 55 6.12.1 Molded Case Circuit Breaker (MCCB) 55 6.12.2 Miniature Circuit Breaker (MCB) 55 6.12.3 Air Break circuit breaker 56 6.12.4 Vacuum circuit breaker 57 6.12.5 SF 6 Circuit Breaker 58 6.13 Protective Relay 59 Page | XIII
6.13.1 Over Current Relay 60 6.13.2 Distance Relay 60 6.13.3 Frequency Relay 61 6.13.4 Trip Relay 61 6.14 Fire Safety Measures 62
CHAPTER 07 OPERATION Topics Page No. 7.1 Gas Booster Compressor 63 7.1.1 Induction Motor 63 7.1.2 Gear Box 63 7.1.3 Centrifugal Compressor 63 7.1.4 Specification of Gas Booster Compressor 64 7.1.5 Schematic Diagram of Gas Booster Compressor 65 7.2 Plant Air and Instrument Air 67 7.3 Water Treatment Plant 67 7.4 Lubricating Oil Pumps 67 7.4.1 Main Lube Pump 67 7.4.2 Auxiliary Lube Oil Pump 67 7.4.3 Emergency Lube Oil Pump 68 7.4.4 Mist Eliminator 68 7.5 Start Up Sequence 69 7.6 Shut Down Sequence 72 7.7 Schematic Diagram of Overall Control System Used in Siddhirganj 2X120 MW Peaking Power Plant 75 7.8 SPEEDTRONIC MARK-VI Control System 81 7.8.1 Common Terminology used in Gas Turbine Logics 81 7.9 Daily Log Sheet of Siddhirganj 2120 MW Peaking Power Plant 82 7.10 Daily Generation Report of Siddhirganj 2120 MW Peaking Power Plant 83 7.11 Palnt Thermal Efficiency& Other Data of Siddhirganj 2120 MW Peaking Power Plant 89
Supplementary Part Topics Page No. Appendix 92 Acronyms 95 Work Cited 97
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List of Figures Topics Page No.
Figure 3.1: Opening Ceremony of Siddhirganj 2120 MW Peaking Power Plant 6 Figure 3.2: Siddhirganj 2120 MW Peaking Power Plant 7 Figure 3.3: Model of Siddhirganj 2120 MW Peaking Power Plant 8 Figure 3.4: Single line diagram of Siddhirganj 2120 MW Peaking Power Plant 9 Figure 3.5: Organogram of Siddhirganj 2120 MW Peaking Power Plant 10 Figure 4.1: Idealized Brayton cycle 11 Figure 4.2: Air extracted from compressor between the sixteenth and seventeenth stage wheels 13 Figure 4.3: 17th stage Compressor Rotor 14 Figure 4.4: Compressor Stator Casing 15 Figure 4.5: Compressor stator and Compressor Stator Blades 16 Figure 4.6: Combustion Chamber looking DOWNSTREAM 17 Figure 4.7: Combustion Liner and Transition Piece 18 Figure 4.8: Crossfire Tubes 19 Figure 4.9: 3 stages Turbine Unit 21 Figure 4.10: Turbine 1 st Stage Bucket 22 Figure 4.11: Turbine Stator 23 Figure 4.12: Turbine 1 st stage nozzle 24 Figure 4.13: Internal view of Turbine 26 Figure 4.14: Exhaust Frame 27 Figure 5.1: Rotating-armature Generator 28 Figure 5.2: Rotating-field Generator 29 Figure 5.3: Simplified Three-Phase AC Generator 30 Figure 5.4: Three-Phase AC Generator 31 Figure 5.5: Generator Compartment of Siddhirganj 2120 MW Peaking Power Plant 32 Figure 5.6: A Stator 33 Figure 5.7: Stator Winding 34 Figure 5.8: A Fully Completed Rotor 35 Figure 5.9: Rectifier Wheel 37 Page | XVI
Figure 5.10: AVR of Siddhirganj 2120 MW PPP 37 Figure 5.11: Block diagram of Brushless Exciter 38 Figure 6.1: Substation switchyard in Siddhirganj Power Plant 42 Figure 6.2: Single Line Diagram of Siddhirgonj 2 120 MW Peaking Power Plant 43 Figure 6.3: Power transformer at Siddhirganj 2120 MW Peaking Power Plant 45 Figure 6.4: Mid Voltage Unit Auxiliary Transformer of Siddhirganj 2120 MW Power Plant 47 Figure 6.5: Auxiliary Transformer of Siddhirganj 2120 MW Power Plant 48 Figure 6.6: Current transformer 49 Figure 6.7: Potential Transformer 49 Figure 6.8: Buchholz Relay 51 Figure 6.9: Lightning Arrester 52 Figure 6.10: Isolator 53 Figure 6.11: Me at switchyard of Siddhirganj 2120 PPP of EGCB 53 Figure 6.12: Switchgear Panel at Siddhirganj 2120 MW Power Plant 54 Figure 6.13: Molded Case Circuit Breaker 55 Figure 6.14: Miniature Circuit Breaker 55 Figure 6.15: Air Break Circuit Breaker 56 Figure 6.16: Vacuum Circuit Breaker 57 Figure 6.17: SF 6 Circuit Breaker 58 Figure 6.18: Relays used in Siddhirganj 2120 MW Peaking Power Plant 59 Figure 6.19: Over Current Relay 60 Figure 6.20: Distance Relay 60 Figure 6.21: Frequency Relay 61 Figure 6.22: Trip Relay 61 Figure 6.23: CO 2 cylinders for fire safety at the Siddhirganj 2120 MW PPP of EGCB 62 Figure 7.1: Gas Booster Compressor Cooling Water System 65 Figure 7.2: Gas Booster Compressor Lube Oil System 65 Figure 7.3: Gas Booster Compressor Process Gas System 66 Figure 7.4: Gas Booster Compressor Bearing Temperature, Vibration & Displacement System 66 Figure 7.5: Mist Eliminator 68 Figure 7.5: Timers & Counters Control System 75 Figure 7.6: Wheelspace Temperature Control System 75 Page | XVII
Figure 7.7: Bearing Temperature Control System 76 Figure 7.8: Vibration Control System 76 Figure 7.9: DLN (Dry Low NOx) Control System 77 Figure 7.10: Flame Control System 77 Figure 7.11: Exhaust Control System 78 Figure 7.12: Synchronization Control System 78 Figure 7.13: IGV (Inlet Guide Vane) Control System 79 Figure 7.14: Startup Control System 79 Figure 7.15: Central Control Room of Siddhirganj 2120 MW Peaking Power Plant 80 Figure 7.16: Daily Log Sheet 82
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List of Tables Topics Page No. Table 2.1: Board of Directors of EGCB Ltd. 3 Table 3.1: Siddhirganj 2120 MW Peaking Power Plant Project 6 Table 5.1: Generator Details of Siddhirganj 2120 MW Peaking Power Plant 32 Table 5.2: Main Exciter details of Siddhirganj 2120 PPP 39 Table 5.3: Pilot Exciter details of Siddhirganj 2120 PPP 39 Table 6.1: Elements of a Substation 44 Table 6.2: Specification of Power Transformer 46 Table 6.3: Specification of Mid Voltage Unit Auxiliary Transformer 46 Table 6.4: Specification of Auxiliary Transformer 47
CHAPTER 01 INTRODUCTION
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1.1 Origin of the Report As a partial fulfillment of Bachelor of Science in Electrical & Electronics Engineering program I have done this practicum report. My report is entitled as "A Study of Siddhirganj 2120 MW Peaking Power Plant of EGCB" in EGCB Ltd. Based on this tow months duration practical experience I have done this report and I have worked under the instruction of Engr. Md. Saiful Islam, Executive Engineer (Electrical), Engr. Abu Sayeed, Sub Divisional Engr. (Electrical), Engr. Md. Golum Mortuza Khan, Deputy Manager (Technical), Engr. Nandhipan Das, Sub-Divisional Engineer (I&C).
1.2 Objectives 1.2.1 Broad Objectives The main objectives are to extrovert my theoretical knowledge to the practical field with adequate conceptualization and understanding the performance of the parameters in case of Power Generation, Operation, Controlling and Protection of Generator, Gas Turbine, Transformer and also Switchgear and Protection systems etc.
1.2.2 Specific Objectives
The specific objectives of this report include:
Study on Gas Turbine, Generator, Transformer, Switchyards Study on Switchgear and Protective Relays Maintenance of Electrical Machines (LV & MV) and Equipments Test and check the equipments of substation Identify different types of problem which arise for operating the plant
1.3 Scope This report will cover the types of machinery used in Siddhirganj 2120 MW Peaking Power Plant, the operating and controlling of these machines, transformer, switchyards and its protection systems, what equipment is placed in which zone, how the equipment has been synthesized etc. The scope will be limited to only this type of power generation, substation & protection system.
1.4 Background Power Plant is one of the few important issues in Bangladesh in generating huge foreign direct investment and also a significant number of employment opportunities. This industry is
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one of the major driving forces of national economy and with the continuous development of technologies worldwide the great demand for electrical energy is a notable feature of the modern civilization. Most of this energy is needed for lighting, heating, domestic appliance, industrial electrical machinery. The importance of electric supply in everyday life has reached such a stage that it is desirable to protect the power system from harm during fault conditions and to ensure maximum continuity of supply. In the Power sector, Power industry of Bangladesh promises to bloom further in the coming years. In our country the crisis of electricity in national grid is a common problem where in industrial sector the electricity is required for 24 hours in a day. The Power Development Board of Bangladesh always trying to overcome this problem by supplying uninterrupted power supply. 1.5 Methodology Both primary and secondary data were collected for the purpose of this report. The report is concentrated of Siddhirganj 2120 MW Peaking Power Plant.
Primary Data: Primary Data were collected from the books about power plants, the User Manual handbooks, Personal interviews with the Engineers, Technicians of the company, official documents of the company and plant Operation Manuals.
Secondary data: Secondary data has been collected from the online sources.
1.6 Limitations This report has some limitations as I could not get the soft copy of data from the computers of company for confidential reasons. I also got very little chance to take photos because some areas are restricted and sensitive. That is why I could gather some photos only from non- restricted area of the company. Therefore, it was not possible to present a complete report like- statistics, financial involvement etc regarding the topic or the opportunity. During the report, it had to be taken care of that the report does not contain any company confidential information and harm the organization in their strategic stance. Two months are not enough time for an authentic study.
CHAPTER 02 ORGANIZATIONAL OVERVIEW
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2.1 Background of EGCB Ltd. On 23rd November 1996 BPDB formed Meghnaghat Power Company (MPC) Ltd. On 16th February 2004 the Meghnaghat Power Company (MPC) Ltd. has been re-named as Electricity Generation Company of Bangladesh (EGCB) Ltd. (an Enterprise of BPDB). Electricity Generation Company of Bangladesh (EGCB) Ltd. (An Enterprise of Bangladesh Power Development Board) was incorporated with Registrar of joint stock companies on February 16, 2004 to produce and sale of Electricity. EGCB has a plan to become a leading electricity generation company across the country. Electricity generation-related business services are among the fastest growing and key area of the economy, EGCB intends to capitalize on the opportunity in that area. The company's major share is currently held by BPDB. 2.2 Board of Directors of EGCB Ltd. 1. Foiz Ahamed, Addl. Secretary (Admin), Power Division, MPEMR. - Chairman 2. Shamima Akhtar, Division Chief (Power), Planning Commission - Director 3. Obaidur Rahman, Director, FBCCI - Director 4. Shah Mohammad Ashraful Hoque, Advocate, Bangladesh Supreme Court - Director 5. Neelufar Ahmed, Director General (DG-2), Prime Minister's Office - Director 6. Syed Mabinul Haque, DG, Monitoring Cell, Finance Division. - Director 7. Md. Abduhu Ruhullah, Chairman, BPDB. - Director 8. Md. Farukuzzaman, Dy-Secretary (Dev.), Power Division. - Director 9. S.M. Monjurul Haque, Memebr, IEB. - Director 10. Jalal Uddin Ahmed Choudhury, Member (Generation), BPDB. - Director 11. Brig Gen. Md. Nazrul Hasan (Retd.), Managing Director, DPDC - Director 12. Md. Mostafa Kamal, Managing Director, EGCB Ltd. - Director
2.4 Vision of EGCB Ltd. "Generation of quality electricity for the betterment of the Nation" 2.5 Mission of EGCB Ltd. "To excel in electricity business by generation efficient, reliable and cost effective electricity in an environmentally responsible manner to satisfy our customers" 2.6 Quality Policy "EGCB is engaged in power generation business. To ensure this EGCB will establish, operate and maintain generation facilities in a cost effective manner. In this process EGCB shall develop and maintain its human, organizational, technological and material resources to ensure continued suitability. The policy will be reviewed from time to time for its continual improvement." 2.7 Core Value E: Excellence: We will make every effort in the pursuit of achieving business Excellence. G: Good Governance: We will manage our business honestly, ethically and in a transparent manner to establish Good Governance and to earn the trust and respect of all our stakeholders. C: Commitment: We will always keep our Commitment to our stakeholders, in the process, we will work together in a spirit of cooperation and trust, taking responsibility and do what is right. B: Boldness: We will always inculcate boldness in all our decisions and actions to constantly improve our performance for meeting the challenges of the future. L: Leadership: We will exercise Leadership by example, demonstrating that we apply our respective professional competencies for creating a work environment to achieve our mission. 2.8 Objectives During project implementation phase: To ensure timely construction and commissioning of Siddhirganj 2120 MW Peaking Power Plant. To ensure timely construction and commissioning of Siddhirganj 450 MW Combined Cycle Power Plant (Erstwhile 2150 MW peaking power plant). To ensure timely construction and commissioning of Haripur 360 MW Combined Cycle Power Plant.
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2.9 Strategies Maintaining suitable organizational system to make it functional to cater to the present and future need and to develop a well-knit management team. Ensuring proper staffing with appropriate job description for every position. In the process to develop human resources continuously. Designing and implementing appropriate reward and incentive schemes to motivate employees and ensure their commitment to the organization. Delegating adequate financial and administrative authority matching with responsibility to the respective officials/executives at different levels. Allocating appropriate resources and logistic support depending on the requirement. Undertaking need-based training programs and human resources development initiatives for the officers and staff of EGCB. Introducing modern management approach and an organizational procedures (operation, maintenance, inventory & procurement, personnel etc.) to be developed, standardized and implemented for improving organizational effectiveness. Support of the govt., Donor etc. to be utilized to take up new projects for generation of electricity. Becoming cost effective by undertaking different measures for cost reduction and efficient fund management. Generate surplus income to invest in growth of the company. In the process to enhance capacity of the plant by replacing old machines and increase generation capacity by adding modern machines. 2.10 Completed Project Siddhirganj 2120 MW Peaking Power Plant Project of EGCB Ltd. Haripur 360 MW Combined Cycle Power Plant Project of EGCB Ltd. 2.11 Upcoming Project Siddhirganj 335 MW Combined Cycle Power Plant Project of EGCB Ltd.
CHAPTER 03 PLANT OVERVIEW
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3.1 Siddhirganj 2120 MW Peaking Power Plant Project The construction of Siddhirganj 2120 MW Peaking Power Plant Project has been completed on the bank of the river Shitalakhya within the Siddhirganj power station premises funded by Asian Development Bank.
Electricity Generation Company of Bangladesh Limited signed a contract with Bharat Heavy Electricals Limited (BHEL) as EPC contractor for the above project on 31 January, 2007. 1st Unit was put on test run on 20 November, 2009 and it was inaugurated by the Honorable Prime Minister on 14 February, 2010. The 2nd Unit was put on test run on 26 May, 2010. The 2nd Unit was taken over from the EPC contractor on October 14, 2010. COD of both units was effective from February 5, 2012.
Figure 3.1: Opening Ceremony of Siddhirganj 2120 MW Peaking Power Plant
Item Particulars Contractor Bharat Heavy Electricals Limited (BHEL), India Site Siddhirganj, Narayanganj Mode of Financing GOB & ADB No. of Unit 2 (Two) Capacity 211.76 MW (2 x 105.88 MW) Fuel Natural Gas Contract Signed 31 January, 2007 Contract Effective Date 16 June, 2007 Inaugurated by Honorable Prime Minister (Unit - 1) 14 February, 2010 Commercial Operation Date 5 February, 2012
Table 3.1: Siddhirganj 2120 MW Peaking Power Plant Project
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3.2 Siddhirganj 2120 MW Peaking Power Plant
Figure 3.2: Siddhirganj 2120 MW Peaking Power Plant
3.3 Land Lease Agreement Land Lease Agreement was signed between EGCB Ltd. & BPDB on 29 August, 2011 for 4.17 acres of land at Siddhirganj power station area on rental basis for the period of 23 years. 3.4 Power Purchase Agreement A Power Purchase Agreement (PPA) for 2x120 MW Peaking Power Plant at Siddhirganj was signed between EGCB Ltd. and BPDB on 29 August, 2011 for the period of 22 years.
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3.5 Model of Siddhirganj 2120 MW Peaking Power Plant
Figure 3.3: Model of Siddhirganj 2120 MW Peaking Power Plant
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3.6 Single line diagram of Siddhirganj 2120 MW Peaking Power Plant
Figure 3.4: Single line diagram of Siddhirganj 2120 MW Peaking Power Plant
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3.7 Organogram of Siddhirganj 2120 MW Peaking Power Plant
Figure 3.5: Organogram of Siddhirganj 2120 MW Peaking Power Plant Chief Engineer Manager (Admin) - 1 Deputy Manager (Admin) - 1 Asstt. Manager (Admin) - 1 Junior AM (Admin) - 1 Sub Divisional Engr. (Tech) - 1
Manager (Accounts) - 1 DM (Accounts) - 1 AM (Accounts) - 1 JAM (Accounts) - 1 Superintending Engr. - 1 (Operation) Superintending Engr. - 1 (Maintenance) Office Asstt./Com. Opt. - 1 Security cum Fire Fighting Supervisor - 1 Executive Engr. (Operation) - 1 Sub Divisional Engr. (General) - 1 Sub Divisional Engr. (Shift) - 1 Sub Divisional Engr. (HSEQ) - 1 Assistant Engr. (Shift) - 12 Sub Assistant Engr. (Shift) - 8 Sub Divisional Engr. (Tech) - 1 Office Asstt./Com. Opt. - 1 Store Keeper - 2 Executive Engr. (Elect. Maint.) - 1 Sub Divisional Engr. (Tech) - 1 Sub Assistant Engr. (Tech) - 2 Executive Engr. (Inst., Measuring, Control and DCS) - 1 Sub Divisional Engr. - 1 Assistant Engr. - 2 Sub Assistant Engr. (Tech) - 2 Executive Engr. (Mech., Civil Maintenance &Workshop) - 1 Sub Divisional Engr. (Tech) - 1 Assistant Engr. (Tech) - 2 Sub Assistant Engr. (Tech) - 2
CHAPTER 04 GAS TURBINE
4.1 General Details Gas Turbine is a modern Power generating equipment. compresses it to sufficiently high combustion, which takes place by in combustion products are generated which are expanded in the turbine where Heat energy of hot combustion products is converted in to mechanical energy of shaft which in turn utilized for generating power in Generator.
Compression is carried out by Axial Flow compressor combustion chambers, Expansion of hot combustible gases is carried Burnt Gases are exhausted to atmosphere or utilized for steam four processes are carried out in only one Factory Turbine. Drawing shows the Typical Brayton Turbine. Gas Turbine operates on segments namely Compression, Heat addition, Expansion and Exhaust.
Process is explained in following diagram on Figure 4.2 Gas Turbine details in Siddhirganj Type Model Turbine Type Turbine Stage R.P.M Output No. of Combustor Compressor Stage Exhaust Temperature (C
All Gas Turbines are Frame -9E machines of GE France make and Mark Power generating equipment. It takes the air from atmosphere t to sufficiently high pressure, same pressurized air is then utilized for , which takes place by in combustion chamber by addition of fuel, there by hot generated which are expanded in the turbine where Heat energy of converted in to mechanical energy of shaft which in turn utilized generating power in Generator. ed out by Axial Flow compressor, Heat addition is done , Expansion of hot combustible gases is carried out in Turbine and Burnt Gases are exhausted to atmosphere or utilized for steam generation in GTs. All of these four processes are carried out in only one Factory assembled Unit which is called Gas Turbine. Drawing shows the Typical Brayton cycle and also shows the components of Gas Turbine. Gas Turbine operates on Brayton Cycle. Brayton cycle is having divided in four Heat addition, Expansion and Exhaust. Process is explained in following diagram on P-V and T-S curve.
Figure 4.1: Idealized Brayton cycle
.2 Gas Turbine details in Siddhirganj 2120 MW Power Plant Open Cycle, Single Shaft, Industrial PG-9171E Axial Flow 3 (Three) 3000 170000 HP 14 (Fourteen) 17 (Seventeen) C ) 543 9E machines of GE France make and Mark-VI controlled.
Page | 11 It takes the air from atmosphere is then utilized for , there by hot generated which are expanded in the turbine where Heat energy of converted in to mechanical energy of shaft which in turn utilized , Heat addition is done by Fuel in in Turbine and generation in GTs. All of these assembled Unit which is called Gas shows the components of Gas Brayton Cycle. Brayton cycle is having divided in four
Cycle, Single Shaft, Industrial controlled.
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PG 9171 E stands for-
PG - Packaged Generator 9 - Frame 9 17 - 17 * 10,000 HP 1 - Single shaft E - Machine series 4.3 Gas Turbine Functional Description When the turbine starting system is actuated and the clutch is engaged, ambient air is drawn through the inlet plenum assembly, filtered, then compressed in the 17th stage, axial flow compressor. For pulsation protection during start-up, the 11th stage extraction valves are open and the variable inlet guide vanes are in the closed position.
When the speed relay corresponding to 95 per cent speed actuates, the 11th stage extraction bleed valves close automatically and the variable inlet guide vane actuator energizes to open the inlet guide vanes (I.G.V.) to the normal turbine operating position. Compressed air from the compressor flows into the annular space surrounding the fourteen combustion chambers, from which it flows into the spaces between the outer combustion casings and the combustion liners. The fuel nozzles introduce the fuel into each of the fourteen combustion chambers where it mixes with the combustion air and is ignited by both (or one, which is sufficient) of the two spark plugs.
At the instant one or both of the two spark plugs equipped combustion chambers is ignited, the remaining combustion chambers are also ignited by crossfire tubes that connect the reaction zones of the combustion chambers. After the turbine rotor approximates operating speed, combustion chamber pressure causes the spark plugs to retract to remove their electrodes from the hot flame zone. The hot gases from the combustion chambers expand into the fourteen separate transition pieces attached to the aft end of the combustion chamber liners and flow towards the three stage turbine section of the machine. Each stage consists of a row of fixed nozzles followed by a row of rotatable turbine buckets. In each nozzle row, the kinetic energy of the jet is increased, with an associated pressure drop, and in each following row of moving buckets, a portion of the kinetic energy of the jet is absorbed as useful work on the turbine rotor. After passing through the 3rd stage buckets, the exhaust gases are directed into the exhaust hood and diffuser which contains a series of turning vanes to turn the gases from the axial direction to a radial direction, thereby minimizing exhaust hood losses. Then, the gases pass into the exhaust plenum.
The resultant shaft rotation is used to turn the generator rotor, and drive certain accessories.
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4.4 Gas Turbine Construction Features Gas Turbine mainly divided in three sections Compressor Combustion system Turbine
4.4.1 Compressor
Introduction The axial flow compressor is consisting of compressor rotor and the enclosing casing. The compressor casing consisting of Inlet Guide Vanes, 17 stages of rotor and stator blades and 2 exit guide vanes. In the compressor, air is compressed in stages by series of alternate rotor and stator airfoil-shaped blades. The rotor blade supply the force needed to compress the air in each stage and stator blade guides the air so that it enters the following rotor stage at proper angle. The compressed air exits through the compressor discharge casing to the combustion chambers. Air is extracted from the compressor for turbine cooling, bearing sealing and during start-up pulsation control.
Compressor Rotor The compressor rotor is an assembly of 15 individual wheels, 2 stub shafts, through bolts, and compressor rotor blades. The first stage blades are mounted on the wheel portion of the forward stub-shaft. Each wheel and wheel portion of each stub-shaft has slots broached around its periphery: rotor blades are inserted into these slots and they are in axial position by stacking at each end of slot. The seventeenth stage wheel has long extension as a flow passage for turbine cooling air that is extracted from compressor between the sixteenth and seventeenth stage wheels.
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Figure 4.2: Air extracted from compressor between the sixteenth and seventeenth stage wheels The air is used to cool: 1. 1st and 2nd stage buckets 2. 2nd stage Aft & 3rd stage forward rotor wheel space 3. Also maintains turbine rotor at Compressor Discharge Temperature (355C) 4. 1st stage wheel space is cooled by air passes through high pressure pacing seal at aft end of compressor rotor
The forward stub shaft is machined to provide the active and inactive thrust faces and journal for No.1 bearing, as well as the sealing surfaces for the No.1 bearing oil seals and the compressor low air pressure seal.
Stages 5, 6, 7 & 8 compressor rotor blades are coated with specialized material to avoid corrosion due to moisture formation at this region
Figure 4.3: 17th stage Compressor Rotor Compressor Stator The stator of compressor is mainly consists of Four major sections Inlet Casing Forward Compressor Casing Aft compressor Casing Compressor discharge casing.
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Figure 4.4: Compressor Stator Casing
These sections, in conjunction with the Turbine shell and exhaust frame form the primary structure of Gas Turbine. They support the rotor at bearing points and constitute the outer wall of gas path. The casing bore is maintained to close tolerances with respect to rotor blade tips for maximum efficiency. The stator blade for stage 1 through 4 is mounted by similar dovetails into ring segments. The ring segments are inserted into circumferential grooves in casing and are held in place with locking keys. In stages 5 through 17, the stator blades and exit guide vanes are inserted directly into circumferential grooves in casing. Locking is used as with the blade ring design.
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Figure 4.5: Compressor stator and Compressor Stator Blades
4.4.2 Combustion Introduction The combustion system is the reverse flow type which includes 14 combustion chambers having the components like: Combustion Liners Flow sleeves Transition pieces Cross fire Tubes Flame detectors Fuel Nozzles Spark plugs
Hot gases generated from burning the fuel in combustion chambers, are used to drive the Turbine. In reverse flow system high pressure air from compressor discharge is directed around the transition pieces and into the annular spaces that surrounds each of 14 combustion liners. Compressor discharge air which surrounds the liner flows radially inward through small holes in liner wall and impinges against rings that brazed to liner wall. This air then flows right toward the liner discharge end and forms a film of air that shields the liner wall from the hot combustion gases. Fuel is supplied to each combustion chamber through a nozzle that functions to disperse and mix the fuel with proper amount of combustion air.
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Combustion chambers Discharge air from axial flow compressor enters the combustion chambers from the cavity at the center of the unit. The air flows upstream along the outside of combustion liner towards liner cap. This air enters the combustion chamber reaction zone through the fuel nozzle swirl tip and through metering holes in both the cap and liner. The hot combustion gases from the reaction zone passes through a thermal soaking zone and then in to dilution zone where additional air is mixed with the combustion gases. Metering holes in dilution zone allow the correct amount of air to enter and cool the gases to the desired temperature. Along the length of the combustion liner and in the liner cap are openings whose function is to provide a film of air for cooling the walls of the liner and cap. The transition pieces direct the hot gases from the liners to the Turbine nozzle
Figure 4.6: Combustion Chamber looking DOWNSTREAM
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Figure 4.7: Combustion Liner and Transition Piece Spark Plugs Combustion is initiated by means of the discharge from two high voltages, retractable electrode spark-plugs installed in adjacent combustion chambers. These spring -injected and pressure retracted plugs receive their energy from ignition transformers. At the time of firing, a spark at one or both of these plugs ignites the combustion gases in the chamber, the gases the remaining chambers are ignited by cross-fire through the tubes that interconnect the reaction zones of remaining chambers. As rotor speed increases, chambers pressure causes the spark plugs to retract and the electrodes are removed from the combustion zones.(spark plug locations at CC: 13 & 14) Ultraviolet flame detectors During the starting sequence, it is essential that an indication of the absence of flame to be transmitted to control system. For this reason, a flame monitoring system is used consisting of four sensors which are installed on tow adjustment combustion chambers and electronic
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amplifier which is mounted in the Turbine control panel. The ultraviolet flame sensor consists of flame sensor, containing a gas filled detector. The Gas within this flame sensor detector is sensitive to the presence of ultraviolet radiation which is emitted by a hydrocarbon flame. A DC voltage, supplied by amplifier, is impressed across the detector terminals. If flame is present, the ionization of gas in the detector allows conduction in the circuit which activates the electronics to give an output defining flame. Conversely, the absence of flame will generate an opposite output defining " No flame ".
The four flame detectors are located in the combustion chamber No 4 , 5 , 10 , 11 out of total 14 combustion chambers.
Fuel nozzles Each combustion chamber is equipped with a fuel nozzle that emits a metered amount of fuel into the combustion liner. Gases fuel is admitted directly into each chamber through metering holes located at the outer edge of the swirl plate. When liquid fuel is used, it is atomized in the nozzle swirl chamber by means of high pressure air. The atomized fuel/air mixture is then sprayed into the combustion zone. Action of the swirl tip imparts a swirl to the combustion air with the result of more complete combustion and essentially smoke free operation of the unit. Crossfire tubes
The 14 combustion chambers are interconnected by means of cross fire tubes. These crossfire tubes propagate the flame to other combustion chambers.
Figure 4.8: Crossfire Tubes
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4.4.3 Turbine The three stage turbine section is the area in which energy in the form of high energy, pressurized gas produced by compressor and combustion section is converted in to mechanical energy.
Rotor The turbine rotor assembly consists of two wheel shafts: the first, second, and third-stage turbine wheels with buckets; and two turbine spacers. Concentricity control is achieved with mating rabbets on the turbine wheels, wheel shafts and spacers. The wheels are held together with through bolts, Selective positioning of rotor members is performed to minimize balance corrections.
The forward wheel shaft extends from the first-stage turbine wheel to the aft flange of the compressor rotor assembly. The journal for the no. 02 bearing is a part of the wheel shaft.
The aft wheel shaft connects from the third-stage turbine wheel to the load coupling. It includes no 03-bearing journal.
Spacers between the first and second, and between the second and third-stage turbine wheels determine the axial position of the individual wheels. These spacers carry the diaphragm sealing bands. The spacer forward face includes radial slots for cooling air passages. The 1-2 spacer also has radial slots for cooling air passages on the aft face.
Turbine rotor must be cooled to maintain reasonable operating temperatures and therefore, assure a longer turbine service life. The turbine rotor is cooled by means of a positive flow of relatively cool( relative to hot gas path air) air extracted from the compressor. Air extracted through the rotor, ahead of the compressor 17th stage, is used for cooling the 1st and 2 nd stage buckets and the 2nd stage aft and 3rd stage forward rotor wheel spaces. This air also maintains the turbine wheels, turbine spacers, and wheel shaft at approximately compressor discharge temperature to assure low steady state thermal gradients thus ensuring long wheel life.
The first stage forward wheel space is cooled by air that passes through the high pressure packing seal at the aft end compressor rotor. The 1st stage aft and 2 nd stage forward wheel spaces are cooled by compressor discharge air that passes through the stage-1 shrouds and then radially inward through the stage-2 nozzle vanes. The 3rd aft wheel space cooled by cooling air that exits from the exhaust frame cooling unit
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Figure 4.9: 3 stages Turbine Unit
Buckets The turbine buckets increase in size from the first stage to the third stage. Because of the pressure reduction resulting from energy conversion in each stage, an increased annulus area is required to accommodate the gas flow. The first stage buckets are the first rotating surfaces encountered by extremely hot gases leaving the first stage nozzle. Each first stage bucket contains a series of longitudinal air passages for bucket cooling. The holes are shaped and sized to obtain optimum cooling of airfoil with the minimum of compressor extraction. Like the first-stage buckets, the second-stage buckets are cooled by span wise air passages the length for the air-foil. Since the lower temperatures surrounding the bucket shanks do not require shank cooling, the second-stage cooling holes are fed by a plenum cast into the bucket shank. Span wise holes provide cooling air to the airfoil at a higher pressure than a design with shank holes. This increases the cooling effectiveness in the airfoil so airfoil cooling is accomplished with minimum penalty to the thermodynamic cycle.
The third stage buckets are not internally air cooled; the tips of these buckets, like the second- stage buckets, are enclosed by a shroud which is a part of the tip seal. The shrouds interlock from bucket to bucket to provide vibration damping.
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Figure 4.10: Turbine 1 st Stage Bucket
Stator Turbine shell The turbine shell controls the axial and radial positions of the shrouds and nozzles. It deter- mines turbine clearances and the relative positions of the nozzles to the turbine buckets. This positioning is critical to gas turbine performance.
Hot gases contained by the turbine shell are a source of heat flow into the shell. To control the shell diameter, it is important that the shell design reduces the heat flow into the shell and limits its temperature. Heat flow limitations incorporate insulation, cooling, and multi-layered structures. The external surface of the shell incorporates cooling air passages. Flow through these passages is generated by an off base cooling fan.
Structurally, the shell forward flange is bolted to flanges at the aft end of the compressor discharge casing and combustion wrapper. The shell aft flange is bolted to the forward flange of the exhaust frame. Trunnions cast onto the sides of the shell are used with similar trunnions on the forward compressor casing to lift the gas turbine when it is separated fromits base.
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Figure 4.11: Turbine Stator
Turbine nozzles In the turbine section, there are three stages of stationary nozzles which direct the high velocity flow of the expanded hot combustion gas against the turbine buckets, causing the rotor to rotate. Because of the high pressure drop across these nozzles, there are seals at both the inside diameters and the outside diameters to prevent loss of system energy by leakage. Since these nozzles operate in the hot combustion gas flow, they are subjected to thermal stresses in addition to gas pressure loadings.
First stage nozzle
The first stage nozzle receives the hot combustion gases from the combustion system via the transition pieces. The transition pieces are sealed to both the outer and inner sidewalls on the entrance side of the nozzle, so minimizing leakage of compressor discharge air into the nozzles. The 18 cast nozzle segments, each with two partitions (or airfoils) are contained by a horizontally split retaining ring which is center-line supported to the turbine shell on lugs at the sides and guided by pins at the top and bottom vertical center-lines. This permits radial growth of the retaining ring, resulting from changes in temperature while the ring remains centered in the shell.
The aft outer diameter of the retaining ring is loaded against the forward face of the first stage turbine shroud and acts as the air seal to prevent leakage of compressor discharge air between the nozzle and shell. On the inner sidewall, the nozzle inner load rail against the first discharge casing. The nozzle is prevented from moving forward by four lugs welded to the aft outside diameter of the retaining ring at These lugs fit in a groove machined in the turbine shell just forward of the first stage shroud T-hook. By moving the horizontal joint support block and the bottom centerline guide pine, the lower half of the nozzle can be rolled out with
Figure Second stage nozzle
Combustion gas exiting from the first stage buckets is again expanded and the second stage turbine buckets by the second stage nozzle.
The second stage nozzle is made of The male hooks on the entrance and exit sides of the sidewall aft side of the first stage shrouds and on the forward maintain the nozzle concentric with the turbine groove fit between nozzle and shrouds segments are held in a circumferential the nozzle outer sidewall. The discharge air.
Third stage nozzle
The third stage nozzle receives the hot gas as it leaves the second stage velocity by pressure drop and directs this flow against the third
the nozzle and shell. On the inner sidewall, the nozzle is sealed by direct bearing of the inner load rail against the first-stage nozzle support ring bolted to the compressor prevented from moving forward by four lugs welded to the aft retaining ring at 45 degrees from vertical and horizontal centerlines. a groove machined in the turbine shell just forward of the first stage shroud By moving the horizontal joint support block and the bottom centerline guide pine, the lower half of the nozzle can be rolled out with the turbine rotor in place. Figure 4.12: Turbine 1 st stage nozzle Combustion gas exiting from the first stage buckets is again expanded and redirected against the second stage turbine buckets by the second stage nozzle. The second stage nozzle is made of 16 cast segments, each with three partitions (or air The male hooks on the entrance and exit sides of the sidewall fit into female grooves on the aft side of the first stage shrouds and on the forward side of the second stage shrouds to maintain the nozzle concentric with the turbine shell and rotor. This close fitting tongue groove fit between nozzle and shrouds acts as an outside diameter air seal. segments are held in a circumferential position by radial pins from the shell into axial slots in second stage nozzle partitions are cooled with compressor The third stage nozzle receives the hot gas as it leaves the second stage buckets, velocity by pressure drop and directs this flow against the third stage buckets.
Page | 24 nozzle is sealed by direct bearing of the nozzle support ring bolted to the compressor prevented from moving forward by four lugs welded to the aft ntal centerlines. a groove machined in the turbine shell just forward of the first stage shroud By moving the horizontal joint support block and the bottom centerline guide pine,
redirected against partitions (or air-foils). fit into female grooves on the second stage shrouds to shell and rotor. This close fitting tongue-and- acts as an outside diameter air seal. The nozzle radial pins from the shell into axial slots in second stage nozzle partitions are cooled with compressor buckets, increases its
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The nozzle consists of 16 cast segments, each with four partitions (or airfoils). It is held at the outer sidewall forward and aft sides in grooves in the turbine shrouds in a manner identical to that used on the second stage nozzle. The third stage nozzle is circumferentially positioned by radial pins from the shell.
The turbine shell and the exhaust frame complete the major portion of the Gas Turbine stator structure. The turbine nozzles , shrouds , No-3 bearing and turbine exhaust diffuser are internally supported from these components.
The turbine shell controls the axial and radial positions of the shrouds and nozzles. Resultantly, it controls turbine clearances and relative positions of the nozzles to the turbine buckets. This positioning is critical to the gas turbine performance.
Hot gases contained by turbine shell are the source of heat flow into the shell.bTo control the shell diameter , it is important to reduce the heat flow into shell by design and to cool it to limit it's temperature. Heat flow limitations incorporate insulation , cooling, and multi- layered structures. The cylindrical portion of shell is cooled by fifth stage air flowing axially through the shell and out through holes in the aft vertical flange into the exhaust frame. The air is then used for further cooling of exhaust frame and third stage aft wheel space.
Structurally , the shell forward flange is bolted to the bulk head at the aft end of compressor discharge casing. The shell aft flange is bolted to the exhaust frame cast onto sides of shell are used to aid in lifting the gas turbine when it is separated from its base , should this ever by necessary.
Diaphragms
Attached to the inside diameters of both the second and third stage nozzle segments are the nozzle diaphragms These diaphragms prevent air leakage past the inner sidewall of the nozzles and the turbine rotor. The high/low, labyrinth-type seal teeth are machined into the inside diameter of the diaphragm. They mate with opposing sealing lands on the turbine rotor. Minimal radial clearance between stationary parts (diaphragm and nozzles) and the moving rotor are essential for maintaining low inter stage leakage; this results in higher turbine efficiency.
Shrouds
Unlike the compressor balding, the turbine bucket tips do not run directly against an integral machined surface of the casing but against annular curved segments called turbine shrouds.
The primary function of the shrouds is to provide a cylindrical surface for minimizing tip clearance leakage.
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The secondary function is to provide a high thermal resistance between the hot gases and the comparatively cool shell. By accomplishing this function, the shell cooling load is drastically reduced, the shell diameter is controlled, the shell roundness is maintained, and important turbine clearances are assured. The shroud segments are maintained in the circumferential position by radial pins from the shell. Joints between shroud segments are sealed by interconnecting tongues and grooves.
Figure 4.13: Internal view of Turbine
4.5 Exhaust Frame and Diffuser The exhaust frame assembly (figure here after) consists of the exhaust frame and the exhaust diffuser. The exhaust frame is bolted to the aft flange of the turbine shell.
Structurally, the frame consists of an outer cylinder and inner cylinder interconnected by ten radial struts. On the inner gas path surfaces of the two cylinders are attached the inner and outer diffusers. The no.3 bearing is supported from the inner cylinder.
The exhaust diffuser, located at the extreme aft end of the gas turbine, bolts to, and is supported by, the exhaust frame. The exhaust frame is a fabricated assembly consisting of an inner cylinder and an outer divergent cylinder that flairs at the exit end at a right angle to the
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turbine centerline. At the exit end of the diffuser between the two cylinders are five turning vanes mounted at the bend. Gases exhausted from the third turbine stage enter the diffuser where velocity is reduced by diffusion and pressure is recovered. At the exit of the diffuser, turning vanes direct the gases into the exhaust plenum. Exhaust frame radial struts cross the exhaust gas stream. These struts position the inner cylinder and n0.3 bearing in relation to the outer casing of the gas turbine. The struts must be maintained at a uniform temperature in order to control the center position of the rotor in relation to the stator. This temperature stabilization is accomplished by protecting the struts from exhaust gases with a metal fairing fabricated into the diffuser and then forcing cooling air into this space around the struts.
Turbine shell cooling air enters the space between the exhaust frame and the diffuser and flows in two directions. The air flows in one direction into the turbine shell cooling annulus and also down through the space between the struts and the airfoil fairings surrounding the struts and subsequently into the load shaft tunnel and turbine third-stage aft wheelspace.
Figure 4.14: Exhaust Frame
CHAPTER 05 GAS TURBINE GENERATOR
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5.1 Generator
Electrical generators are devices that convert mechanical energy into electric energy. The mechanical energy in turn is produced from chemical or nuclear energy in various types of fuel, or obtained from renewable sources such as wind or falling water. Most alternators use a rotating magnetic field. In principle, any AC electrical generator can be called an alternator, Alternators in power stations driven by turbines are called turbo-alternators or primover.AC generator or Alternators operate at the same fundamental principles of electromagnetic induction as DC generator. They also consist of an armature winding and magnetic field. But there is important difference between the two. Whereas in DC generators the armature rotates and the field system is stationary, the arrangement in armature is just the reverse of it. In their case standard construction consist of armature winding mounted on a stationary element called stator and field windings on a rotating element called rotor. 5.2 Generator Types Rotating-armature generators Rotating-field Generators 5.2.1 Rotating-armature Generators
Figure 5.1: Rotating-armature Generator
In the rotating armature AC generator as illustrated in Figure 4.1, the stator provides a stationary electromagnetic field. The rotor, acting as the armature, rotates in the field, cutting the lines of force and producing the desired output voltage. The output voltage is taken from
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the rotor by the slip rings and brushes. One slip ring is attached to each end of the rotating loop. The brushes make sliding electrical contact with the slip rings. The generator's AC output voltage can be transferred from the slip rings through the brushes to an external circuit. Rotating armature AC generators are typically used in applications involving small amounts of power. With larger amounts of power, a great deal more current flow occurs through the slip rings and brushes. It is difficult and expensive to build slip rings and brushes to carry large amounts of current. Therefore, most large AC generators are rotating field generators. 5.2.2 Rotating-field Generators Figure 5.2: Rotating-field Generator The rotating field AC generator as illustrated in Figure 4.2 is by far the most widely used generator. In this type of generator, direct current from a separate source is passed through windings on the rotor by means of slip rings and brushes. This maintains a rotating electromagnetic field of fixed polarity (similar to a rotating bar magnet). The rotating magnetic field of the rotor extends outward and cuts through the armature windings embedded in the surrounding stator. As the rotor turns, alternating voltages are induced in the windings because
magnetic fields of first one polarity and then the other cut through them. Because the output power is taken from stationary windings, the output may be connected through fixed terminals. The advantage in this type of construction is that larger amounts of currents can be
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handled because there are no sliding contacts and the whole output circuit is continuously insulated. 5.3 Polyphase Generators Most electric power is generated and distributed as three-phase rather than single-phase power for the following reasons:
The cost of transmission is less than for the same voltage and power in a single-phase system.
A three-phase generator has a 180% greater capacity than a single phase generator of the same physical size.
Single-phase voltage and power is easily available from a three-phase system by merely tapping any two of the power leads.
A three-phase AC generator is designed to produce three-phase AC power by building more coils in the stator around the rotor. The three coils are equally spaced 120 apart around the inside of the stator. The armature coils are wired so that the generator has three separate output voltages that differ in phase by 120.
Figure 5.3: Simplified Three-Phase AC Generator
Figure 4.3 illustrates a simplified three-phase, two pole AC generator. Each of the three coils generates an AC voltage sine wave as illustrated in Figure 4.4 (a) and 4.4 (b). The voltage wave (phase) B begins one third of the way into the A wave cycle, and the C wave begins two thirds of the way into the A wave cycle. This relationship is caused by the position of the coils in the stator. When the voltage in phase A has reached its peak positive value and is
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returning to zero, the voltage in phase B has reached its peak negative value and is beginning to return to zero. The voltage in phase C has passed zero and a negative voltage is being induced. During a three-phase voltage cycle, the overall voltage induced is never zero.
Figure 5.4: Three-Phase AC Generator 5.4 Generator Details of Siddhirganj 2120 MW Peaking Power Plant The power plant includes Gas turbine, generator and the auxiliary equipment needed for power production. The gas turbine and the generator are mounted on a common base frame, constituting a generating set. In Siddhirganj 2120 MW power plant there are 2 Power generating units.
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Type TARI 1080-36P Manufacture BHEL, India Drive Gas Turbine Output power 108600KW Apparent power 135750 KVA P.f 0.80 R.P.M 3000 Phase 3 Stator Volt. 11000V Stator Current 7125A Rotor Volt. 370V Rotor Current 817A Cooling CACW Total Weight 210 Tons Year 2008
Table 5.1: Generator Details of Siddhirganj 2120 MW Peaking Power Plant
Figure 5.5: Generator Compartment of Siddhirganj 2120 MW Peaking Power Plant
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5.5 Different parts of Generator 5.5.1 Stator Stator is a stationary part of a generator which is a tight construction supporting and enclosing stator winding, core. The generator is driven by a direct coupled by gear box with gas turbine at the speed of 3000 rpm. The generator is designed for continuous rated output. Temperature detector or other devices installed or connected within the machine, permits the winding core and cooling temperature, pressure and purity in machine.
Figure 5.6: A Stator
Stator frame
The stator frame is used for housing armature conductors. It is made of cylindrical section with two end shields which are gas tight and pressure resistant. The stator frame accommodates the electrically active parts of stator i.e. the stator core and stator winding. The fabricated inner cage is inserted in the outer frame after the stator has been constructed and the winding completed.
Stator core
The stator core is stacked from the insulated electrical sheet steel lamination and mounted in supporting rings over the insulated dovetail guide bars. In order to minimize eddy current losses core is made of thin laminations. Each lamination layer is made of individual sections. The ventilation ducts are imposed so as to distribute the gas accurately over the core and in particularly to give adequate support to the teeth. The main features of core are:
1. To provide mechanical support. 2. To carry efficiently electric, magnetic flux. 3. To ensure the perfect link between the core and rotor.
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Stator winding The stator winding is the noble part of the generator .It composed of conductors wedged into the magnetic core. It is the winding that the electrical energy is generated, and it is from the winding that is energy must be channeled outside. There are two distinct parts of the winding:
1. The straight part which the magnetic core, 2. The end windings which are outside the core and which serve to connect bars of different slots together, thereby completing the winding. Each conductor must be capable of carrying rated current without overheating. The stator winding consists of two layers made up of individual bars. Windings for the stators are made of copper strips wound with insulated tape which is impregnated with varnish, dried under vacuum and hot pressed to form a solid insulation bar. These bars are then placed in the stator slots and held in with wedges to form the end turns. These end turns are rigidly placed and packed with blocks of insulation material to withstand heavy pressure. The electrical connection between top and bottom bars is made by connecting sleeve. Class F insulation is used.
Figure 5.7: Stator Winding
5.5.2 Rotor The moving or rotating part of generator is known as rotor. The axial length of shaft of the rotor is very large as compared to its diameter in case of generators. It is coiled heavily (field coils) as it has to support large amount of current and voltage. Rotor revolves in most
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generators at a speed of 3000 RPM. Field coils are wound over it to make the magnetic poles and to maintain magnetic strength the winding must carry a very high current.
Figure 5.8: A Fully Completed Rotor
Rotor shaft Rotor shaft is a single piece. The longitudinal slots are distributed over its circumference. The rotor consists of electrically active portion and two shaft ends approximately 60 % of rotor body circumference have longitudinal slots which hold the field winding. Slots pitch is selected so that the two solid poles are displaced by 180 degree the rotor wedges act as damper winding within the range of winding slots. Rotor winding Rotor winding involves coiling of rotor. Rotor coils are made of pure copper +0.2% silver, which has high tensile as well as temperature bearing properties. The coil doesnt deform even at high temperatures as on adding silver the thermal stresses are eliminated. Rotor winding is also known as field winding which is wound in longitudinal slots in rotor. The windings consist of several coils inserted into the slots and series connected such that two coil groups form one pole. Each coil consists of several series connected turns, each of which consists of two half turns connected by brazing in the end section. The rotor bearing is made of silver bearing copper ensuring an increased thermal stability. The individual turns of coils are insulated against each other by interlayer insulation. The slot wedges are made of high electrical conductivity material and thus act as damper windings. At their ends the slot wedges are short circuited through the rotor body. When rotor is rotating at high speed, the centrifugal forces tries to lift the winding out of slots, they are contained by wedges.
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5.5.3 Bearings The generators are provided with pressure lubricated self-aligning type journal bearing to ensure higher mechanical stability and reduced vibration in operation. The bearings are provided with suitable temperature element to monitor bearing metal temperature in operation. The temperature of each bearing monitored with two RTDs embedded in the bearing sleeve such that the measuring point is located directly below Babbitt. Bearing have provision for vibration pickup to monitor shaft vibration. To prevent damage to the journal due to shaft current, bearings and coil piping on either side of the non-drive and bearings are insulated from the foundation frame. 5.5.4 Coupling Coupling is made with screws and fitting between the Generator and exciter rotor. The screws are made out of low alloy steel with high mechanical properties. This coupling provided torque transmission between the generator and exciter rotor. 5.6 Excitation System The basic use of exciter system is to produce necessary DC for field windings of generator system. The brushless exciter mainly consists of Rectifier wheels Main exciter Pilot exciter Metering and supervisory equipment 5.6.1 Rectifier Wheels The main components to the rectifier wheel are the silicon diodes which are arranged in the rectifier wheel in a three phase bridge circuit. One diode each is mounted in each aluminum alloy heat sink and connected in parallel associated with each diode is a fuse which serves to switch off the diode if it fails. It supplies DC to the generators field from main exciters AC output.
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Figure 5.9: Rectifier Wheel 5.6.2 Automatic Voltage Regulator (AVR) Automatic Voltage Regulator (AVR) forms a part of the excitation system for a brush-less generator. The AVR is connected in series to the pilot exciter. The AVR controls the power fed to the exciter field, and hence the main field, to maintain the machine output voltage within the specified limits, compensating for load, speed, temperature and power factor of the generator. The AVR is linked with the main stator windings and the exciter field windings to provide closed loop control of the output voltage with load regulation of +/- 1.0%.
Figure 5.10: AVR of Siddhirganj 2120 MW PPP
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5.6.3 Main Exciter Three-phase main exciter is a six pole revolving armature unit. Arranged in the stator frame are the poles with the field and damper winding and a quadrature-axis measuring coil for measurement of the field current. The rotor consists of stacked laminations which are compressed by through bolts over compression rings. The three phase winding is inserted in the slots of the laminated rotor. 5.6.4 Pilot Exciter The three phase pilot exciter is a six pole revolving field unit with permanent-magnet poles. The frame accommodates the laminated core with the three phase winding. The rotor has mounted pole. Each pole is housed in a non magnetic metallic enclosure through which the cooling air circulates. 5.7 Functional Description of Excitation System The three-phase pilot exciter has a revolving field with permanent-magnet poles. The three- phase AC generated by the permanent-magnet pilot exciter is rectified and controlled by the AVR to provide a variable DC current for exciting the main exciter. The three-phase AC induced in the rotor of the main exciter is rectified by the rotating rectifier bridge and fed to the field winding of the generator rotor through the dc lead in the rotor shaft. A common shaft carries the rectifier wheel, the rotor of the main exciter and the permanent-magnet rotor of the pilot exciter. The shaft is rigidly coupled to the generator pilot exciter. The generator and exciter rotors are thus supported on a total of three bearing.
Figure 5.11: Block diagram of Brushless Exciter
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5.8 Exciter Details of Siddhirganj 2120 MW Peaking Power Plant Main Exciter Type EAR 54/34-30/6-4 Manufacture BHEL, India Output 583KW R.P.M 3000 Phase 3 Volt. 550V Current 1060A Insulation Class F Year 2007 Table 5.2: Main Exciter details of Siddhirganj 2120 PPP
Pilot Exciter Type EAP 30/12-30/6 Manufacture BHEL, India Pole 6 R.P.M 3000 Phase 3 Volt. 180V Current 26A Year 2007
Table 5.3: Pilot Exciter details of Siddhirganj 2120 PPP
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5.9 Generator Protections
The core of an electrical power system is the generator. The conversion of the fundamental energy into its electrical equivalent requires a prime mover to develop mechanical power as an intermediate stage. The nature of this machine depends upon the source of energy and in turn this has some bearing on the design of the generator. Gas is the main fuel in the EGCB power plant. Some important generator protections used at EGCB are -
Over Current Protection Over Voltage Protection Frequency Protection Frequency Relay Rotor Earth Fault Protection Under Excitation (Loss of field) Protection
5.9.1 Over Current Protection
If a short circuit occurs, the circuit impedance is reduced to a low value and therefore a fault is accompanied by a large current. Over-current relays sense fault currents and also over-load currents.
5.9.2 Over Voltage Protection
Over-voltage protection serves to protect the electrical machine and connected electrical plant components from the effects of inadmissible voltage increase. Over voltage can be caused by incorrect manual operation of the excitation system, faulty operation of the automatic voltage regulator, (full) load shedding of a generator, separation of the generator from the system etc.
5.9.3 Frequency Protection
The frequency protection function detects abnormally high and low frequencies of the generator. If the frequency lies outside the admissible range, appropriate actions are initiated, such as separating the generator from the system. An increase in system frequency occurs when large load-share is removed from the system and a decrease in system frequency occurs when the system experiences an increase in real power demand.
5.9.4 Frequency Relay
The frequency of induced electromotive force (EMF) of synchronous generators is maintained constant by constant speed. A frequency relay works at a predetermined value of frequency. It may be an over-frequency relay, an under-frequency relay, or a combination of both. Frequency relays are used in generator protection and for load-frequency control.
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5.9.5 Rotor Earth Fault Protection
Rotor earth fault protection is used to detect earth faults in the excitation circuit of synchronous machines. An earth fault in the rotor winding does not cause immediate damage. However, if a second earth fault occurs it constitutes a winding short-circuit of the excitation circuit. The resulting magnetic imbalances can cause extreme mechanical forces which may destroy the machine.
5.9.6 Under Excitation (Loss of field) Protection
The under excitation protection protects a synchronous machine from asynchronous operation in the event of faulty excitation or regulation and from local overheating of the rotor. Furthermore, it avoids endangering network stability by under excitation of large synchronous machines.
CHAPTER 06 SUBSTATION AND SWITCHGEAR
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6.1 Substation A substation is a part of an electrical generation, transmission, and distribution system. Substations transform voltage from high to low, or the reverse, or perform any of several other important functions. Between the generating station and consumer, electric power may flow through several substations at different voltage levels. A substation that has a step-up transformer increases the voltage while decreasing the current, while a step-down transformer decreases the voltage while increasing the current for domestic and commercial distribution. A substation is a high-voltage electric facility. It is used to switch generators, equipment and circuits or lines in and out of system.
Figure 6.1: Substation switchyard in Siddhirganj Power Plant Main specific parts of substation are: Power and Auxiliary transformers Local network for Connection point Bus bars, circuit breakers, disconnections Measuring point for control center - Potential and current transformers Fuses, Relays and other protection device
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6.1.1 Substation Arrangement of Siddhirganj 2120 MW Power Plant The substation arrangement of Siddhirganj 2120 MW Power Plant is 1. At Generating Stations: Using power transformer step up voltage to higher level say 11 KV to 132 KV. 2. At load center: Where voltage is getting down 11 KV to 400 Volts using transformer and this is near to be load center. 6.1.2 Substation Layout of Siddhirganj 2120 MW Power Plant Substation layout consists essentially in arranging a number of switchgear components in an ordered pattern governed by their function and rules of spatial separation.
Figure 6.2: Single Line Diagram of Siddhirgonj 2 120 MW Peaking Power Plant
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6.2 Elements of a Substation Substations have one or more transformers, switching and control equipment. In a substation, circuits breakers are used to interrupt any short-circuit or overload currents that may occur on the network. Substations do not usually have generators, although a power plant may have a substation nearby. Other devices such as power factor correction capacitors, synchronizer and voltage regulators may also be located at a substation. The main equipments of a substation are shown below: Equipment Function Bus-bar
Incoming and outgoing lines are connected to the bus- bars. Isolator
Disconnect a part of the system for general maintenance and repair under no load condition for safety. Earthling Switch
Discharge the over voltage to earth. Circuit Breaker
Which can automatic open or close a circuit under normal as well as fault condition. Lightning Arrestor
To discharge lightning over voltages and switching over voltages to earth. Current Transformer
Step down current to know the ratio for control and protection. Voltage Transformer
Step down voltage to know the ratio for control and protection. Series Reactors
Reduce the short circuit current or starting current. Power Transformer Step up or step down the voltage and transfer power at the same frequency. Coupling Capacitor
Provide connection between high voltage line and power line current carrier equipment. Series Capacitors
Compensation of series reactance of long lines. Shunt capacitors
Provide compensation to reactive loads of lagging power factors. Neutral Grounding Resistor Limit the earth current.
Table 6.1: Elements of a Substation
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6.3 Power Transformer Generation of Electrical Power in low voltage level is very much cost effective. Hence Electrical Power is generated in low voltage level. Theoretically, this low voltage leveled power can be transmitted to the receiving end. But if the voltage level of a power is increased, the electric current of the power is reduced which causes reduction in ohmic or I 2 R losses in the system. Because of these, low leveled power must be stepped up for efficient electrical power transmission. This is done by step up transformer at the sending side of the power system network. As this high voltage power may not be distributed to the consumers directly, this must be stepped down to the desired level at the receiving end with help of step down transformer. These are the use of electrical power transformer in the Electrical Power System.
Figure 6.3: Power transformer at Siddhirganj 2120 MW Peaking Power Plant Siddhirganj 2120 MW Peaking Power Plant has two 132/11 KV three phase power Transformer.
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The details information of power transformers is given bellow: Manufacture BHEL, India 2008 Rating 170 MVA Rated Voltage LV-11 KV, HV-132 KV Rated Current LV-7138.15 A, HV-594.85A No. of Phase Three (3- ) Frequency 50 Hz Tapping 5 (Five) Step, 5% Type of Cooling ONAN/ONAF/OFAF Connection Symbol YNd1 Maximum Temp. Rise Oil-50 C, Winding-55 Oil 60800 Liter Weight of Core and Coil 94800 Kg Total Weight 205200 kg
Table 6.2: Specification of Power Transformer
6.4 Mid Voltage Unit Auxiliary Transformer MVUAT or Mid Voltage Unit Auxiliary Transformer is used as a step down transformer here at Siddhirganj 2120 MW Power Plant. It steps down the voltage to 6.6KV from 11KV for auxiliary plant equipments that require 6.6KV to operated such as GBC and starting motor. In Siddhirganj 2120 MW Power Plant There are two MVUAT for two units. The details information Mid Voltage Unit Auxiliary is given below: Manufacture BHEL, India 2008 Rating 12.50 MVA Rated Voltage LV-6.6 KV, HV-11 KV Rated Current LV-1045.92A, HV-656.08A No. of Phase Three (3- ) Frequency 50 Hz Tapping 5 (Five) Step, 5% Type of Cooling ONAN/ONAF Connection Symbol Dyn1 Maximum Temp. Rise Oil-50 C, Winding-55 Oil 10600 Liter Weight of Core and Coil 15000 Kg Total Weight 35500kg
Table 6.3: Specification of Mid Voltage Unit Auxiliary Transformer
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Figure 6.4: Mid Voltage Unit Auxiliary Transformer of Siddhirganj 2120 MW Power Plant 6.5 Auxiliary Transformer Auxiliary transformer is used to supply low voltage for AC power system inside substation such as lighting, air conditioners and other AC supply system. The Plant has 4 auxiliary transformers. The detail information about the transformers is given below: Manufacture EMCO Ltd, India 2008 Rating 1600 KVA Rated Voltage LV-440 KV, HV-6.6 KV Rated Current LV-2200A, HV-140A No. of Phase Three (3- ) Frequency 50 Hz Type of Cooling ONAN Connection Symbol Dyn11 Maximum Temp. Rise Oil-50 C, Winding-55 Oil 920 Liter Weight of Core and Coil 2070 Kg Total Weight 4550 Kg
Table 6.4: Specification of Auxiliary Transformer
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Figure 6.5: Auxiliary Transformer of Siddhirganj 2120 MW Power Plant
6.6 Instrument Transformer
Instrument transformers are used for accurate and reliable current and voltage measurements for secondary equipments such as meters, protection relays and other devices measurements which provide safe and efficient operation of transmission networks. Instrument transformers include:
Current Transformer (CT) Potential Transformer (PT)
6.6.1 Current Transformer
A current transformer is used in high voltage circuits where it is not possible to measure current directly. CT steps down high current to very low current that can be handled easily and thus can be read. Its secondary is connected to an ammeter of very small capacity (usually 5 A) but its scale is calibrated according to actual values. A current transformer is selected according to the ratio of maximum load current and required current. For EGCB power plant, the CT ratio is 800/1 for 132 KV line current.
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Figure 6.6: Current transformer
6.6.2 Potential Transformer
Potential transformers have a large number of primary turns and a small number of secondary turns and may be either single phase or three phase units. For EGCB the PT ratio is 1200/1 for 132 KV line. This means that the PT converts the 132 KV voltage into 110 V voltage, measures the voltage with a meter and applies a user programmed multiplier (1200) to this number (110 V) to calculate the original voltage. The output seen by the user is after the multiplication.
Figure 6.7: Potential Transformer
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6.7 Transformer Protection
In a transformer, fault occurs due to insulation breakdown, aging of insulation, overheating due to over excitation, oil contamination and leakage or reduced cooling. Hence a reliable, secure and fast protection system for the transformer is essential to minimize the damage. In order to get an early warning and to minimize the damage in case of fault, it is necessary to equip the transformer with monitors and protective relays. Some important transformer protections used at EGCB are -
The differential relay compares between primary current and secondary current of power transformer. If there is any unbalance found, the relay will actuate and inter-trip both the primary and secondary circuit breaker of the transformer.
6.7.2 Protective Relay
The choice of protection depends upon several aspects such as type and rating of the protected equipment, its importance, location, probable abnormal conditions, cost etc. A fault is a defect in an electrical circuit due to which the flow of current is diverted from the intended path. The protective relaying senses the abnormal conditions in a part of the power system due to a fault and gives an alarm or isolates that part from the healthy system.
6.7.3 Over-current Relay
Over-current relaying is the simplest and cheapest, the most difficult to apply, and the quickest to need readjustment or even replacement as a system changes. If a short circuit occurs, the circuit impedance is reduced to a low value, and therefore a fault is accompanied by large current. Over current relays sense fault currents and also overload currents. It is generally used for phase and ground-fault protection.
6.7.4 Distance Relay
Distance relays are double actuating quantity relays with one coil energized by current. When over-current relay does not work properly, distance relay should be considered. During a fault on a transmission line, the fault current increases and the voltage at fault point reduces. If fault is nearer the relay, measured voltage is lesser. If fault is further from the relay, measured
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voltage is more. Hence assuming constant fault resistance, each value of V/I measured from relay location corresponds to distance between the relaying point and the fault along the line. Hence such protection is called distance protection.
6.7.5 Buchholz Relay
In the field of electric power distribution and transmission, a Buchholz relay is a safety device mounted on some oil-filled power transformers and reactors, equipped with an external overhead oil reservoir called a "conservator". The Buchholz Relay is used as a protective device sensitive to the effects of dielectric failure inside the equipment. I saw Buchholz relay on the top of the 11/132 KV transformer.
Figure 6.8: Buchholz Relay
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6.8 Lightning Arrester A lightning arrester is a device used in electrical power systems to protect the insulation and conductors of the system from the damaging effects of lightning. The typical lightning arrester has a high-voltage terminal and a ground terminal. When a lightning surge travels along the power line to the arrester, the current from the surge is diverted through the arrester, in most cases to earth. I saw lightning arrester near the 11/132 KV transformer (132 KV side).
Figure 6.9: Lightning Arrester
6.9 Isolator
Isolator is used to isolate the circuit permanently after a fault. The main difference between isolator and circuit breaker is that isolator is an off-load device, whereas circuit breaker is an on-load device. An off-load device is a switch where there is no current passing through it when it is switched. In an on-load device current passes through when it is switched. There are three isolators at 132 KV switch yard at EGCB, both of which are motor operated (can be control from the control room) and manual gear operated.
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Figure 6.10: Isolator
Figure 6.11: Me at switchyard of Siddhirganj 2120 PPP of EGCB
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6.10 Switchgear The term switchgear, used in association with the electric power system, or grid, refers to electrical equipments like isolators, fuses, relays, circuit breakers which intended to connect and disconnect power circuits are known collectively as switchgear. Switchgear is used in connect with generation, transmission, distribution and conversion of electric power for controlling, metering, protecting and regulating devices.
Figure 6.12: Switchgear Panel at Siddhirganj 2120 MW Power Plant
6.11 Circuit breaker A circuit breaker (CB) is an automatic switch that stops the flow of electric current in a suddenly overloaded or otherwise abnormally stressed electric circuit. During abnormal conditions, when excessive current develops, a circuit breaker opens to protect equipment and surroundings from possible damage due to excess current. A CB does not need to be replaced like a fuse after each operation. It can be reset either manually or automatically to its normal operating condition.
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6.12 Circuit Breaker Used in Siddhirganj 2120 MW Peaking Power Plant 6.12.1 Molded Case Circuit Breaker (MCCB) Molded case circuit breaker operation as like as thermal or thermal-magnetic operation and rated current start from100A. The MCCB may be used as an incoming device, but it is more generally used as an outgoing device on the load side of a switchboard. It is normally mounted into a low-voltage switchboard or a purpose-designed panel board.
Figure 6.13: Molded Case Circuit Breaker 6.12.2 Miniature Circuit Breaker (MCB) Miniature circuit breakers rated current not more than 100A. Trip characteristics normally are not adjustable. The miniature circuit breaker (MCB) has a contact system and means of arc quenching, a mechanism and tripping and protection system to open the circuit breaker under fault conditions.
Figure 6.14: Miniature Circuit Breaker
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6.12.3 Air Break circuit breaker In air circuit breakers air is used as arc quenching media. These circuit breakers employ high resistance interruption principle. The arc is rapidly lengthened by means of the arc runners and arc chutes and the resistance of the arc is increased by cooling, lengthening and splitting the arc. The arc resistance increases to such an extent that the voltage drop across the arc becomes more than the supply voltage and the arc extinguished. Air breaker circuit breakers are used in d.c circuits and a.c circuits up to 12 kV. Magnetic field is utilized for lengthening the arc in high voltage air break circuit breaker. The arc resistance is increased to such an extent that the system voltage cannot maintain the arc and the arc get extinguished. Specification of Air Break circuit breaker is given below: Type :AH-12D-CS Rated frequency :50 -60Hz Rated Voltage :415V Rated Current :1250 A Breaking capacity :50KA(for 1sec) Supply Voltage Tripping :110 V/DC Supply Voltage Closing : 110 V/DC
Figure 6.15: Air Break Circuit Breaker
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6.12.4 Vacuum circuit breaker Vacuum circuit breaker with rated current up to 3000 A, these breakers interrupts the current by creating and extinguishing the arc in a vacuum container. Vacuum circuit breakers tend to have longer life expectancies between overhaul than do air circuit breakers. In a vacuum circuit breaker, two electrical contacts are enclosed in a vacuum. One of the contacts is fixed, and one of the contacts is movable. When the circuit breaker detects a dangerous situation, the movable contact pulls away from the fixed contact, interrupting the current.
Specification of Vacuum Circuit Breaker is given below:
Type :B/BARET Rated frequency :50Hz Rated Voltage :7.2KV Short Time Current :40 A Duration of short circuit : 1sec Rated Short circuit breaking current :16KA Making Capability :100KAP Impulse Withstand :60KVP Spring Coil :110V
Figure 6.16: Vacuum Circuit Breaker
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6.12.5 SF 6 Circuit Breaker A circuit breaker in which the current carrying contacts operate in sulphur hexafluoride or SF 6 gas is known as an SF 6 circuit breaker. SF 6 has excellent insulating property. SF 6 has high electro-negativity. That means it has high affinity of absorbing free electron. Whenever a free electron collides with the SF 6 gas molecule, it is absorbed by that gas molecule and forms a negative ion. SF 6 Circuit Breakers has a superior arc quenching medium so the arcing time is very short. The SF 6 Circuit Breakers have been found very effective for high power and high voltage service.
Specification of SF 6 Circuit Breaker is given below: Type :ETK 24 Rated frequency :50Hz Rated Voltage :12-17.5kV Rated Current :1250 A Duration of short circuit : 3sec Rated Short circuit breaking current :16KA Lightning impulse withstand voltage : 125KV Rated break time :45-50ms Rated make time :65-70ms
Figure 6.17: SF 6 Circuit Breaker
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6.13 Protective Relay AC power system is covered by several protection zones. Each protective zone covers one or two components of the system. The neighboring protective zones overlap so that no part of the system is left unprotected. During the abnormal situation, the protective relaying senses the condition and closes the trip circuit of the circuit breaker. The protective schemes for large electrical equipment comprise several types of protective systems. For low voltage equipment of relatively small ratings, fuses and thermal relays are generally adequate. The protective schemes for large power system equipment is generally designed with due regards to power swings, power system stability and associated problems.
Types of Protective Relays:
Differential Relay Over current/earth fault Relay Frequency Relay Trip Relay Lockout Relay Distance Relay Time Relay
Figure 6.18: Relays used in Siddhirganj 2120 MW Peaking Power Plant
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6.13.1 Over Current Relay
An "over current relay" is a type of protective relay which operates when the load current exceeds a preset value. In a typical application the over current relay is connected to a current transformer and calibrated to operate at or above a specific current level. When the relay operates, one or more contacts will operate and energize to trip (open) a circuit breaker.
Figure 6.19: Over Current Relay
6.13.2 Distance Relay
The most common form of protection on high voltage transmission systems is distance relay protection. Power lines have set impedance per kilometer and using this value and comparing voltage and current the distance to a fault can be determined. The ANSI standard device number for a distance relay is 21.
Figure 6.20: Distance Relay
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6.13.3 Frequency Relay Frequency relays monitor for overshooting and undershooting against the set frequency thresholds in 50 Hz or 60 Hz systems. The frequency relay is designed to be used for the protection of power generators and other AC equipment against over frequency and under frequency
Figure 6.21: Frequency Relay
6.13.4 Trip Relay In a protection system the trip circuit of the circuit breaker is crucial. If an interruption occurs in the trip circuit a possible network fault will not be disconnected and would have to be cleared by another protection upstream in the power system.
Figure 6.22: Trip Relay
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6.14 Fire Safety Measures
There were a couple of cylinders having Carbon-Di-Oxide gas. This gas can be used through pipes in combustion chamber and other important areas. Gas containing capacity of each cylinder is 6000 Kg. It can be controlled by both automatic and manual process.
Figure 6.23: CO 2 cylinders for fire safety at the Siddhirganj 2120 MW PPP of EGCB
CHAPTER 07 OPERATION
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7.1 Gas Booster Compressor
Gas booster compressor (GBC) is an important part of the Siddhirganj 2120 MW Peaking Power Plant. It is used to boost up the speed of the gas. The gas supplied from Titas is not fully pressurized enough for combustion. There are a lot of pneumatic valves in this plant. Some get air from bottom and some get air from top. The ones which get air from the top are called air to open and the ones which get air from the bottom are called air to close. It has a suction line and a discharge line. The discharge gas has high temperature and pressure. Discharge temperature is 135C and pressure is 25 kg. Gas cooler is used to reduce the temperature of the gas. When the turbine is not started, the discharge gas is again fed into the suction line through an anti-surge valve. Anti-surge valve is used to reduce the pressure of the feeder gas.
Gas booster compressor consists of -
Induction Motor Gear Box centrifugal compressor
7.1.1 Induction Motor
GBC use induction motor for start GBC, An induction or asynchronous motor is a type of AC motor where power is supplied to the rotor by means of electromagnetic induction. These motors are widely used in industrial drives, particularly poly phase induction motors, because they are robust and have no brushes. Their speed can be controlled with a variable frequency drive.
7.1.2 Gear Box
The fixed speed motor speed does not fall within the compressor speed operational window a speed changing gearbox is required. The gearbox is used to increase the motor speed to match compressor gas. For induction motor systems, the gearbox ratio selection should take into account the slip speed of the motor in the effective speed. 7.1.3 Centrifugal Compressor Gas from a pure natural gas wellhead might have sufficient pressure to feed directly into a pipeline transport system. Gas from separators has generally lost so much pressure that it must be recompressed to be transported. Turbine driven compressors gain their energy by using a small proportion of the natural gas that they compress. The turbine itself serves to operate a centrifugal compressor, which contains a type of fan that compresses and pumps the natural gas through the pipeline. Some compressor stations are operated by using an electric motor to turn the same type of centrifugal compressor. This type of compression does not
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require the use of any of the natural gas from the pipe; however it does require a reliable source of electricity nearby. The compression includes a large section of associated equipment such as scrubbers (to remove liquid droplets) and heat exchangers, lube oil treatment etc.
7.1.4 Specification of Gas Booster Compressor
No. of compressor : 03 (Three)
Compressor: Compressor Type : BCL406 First Critical Speed : 5800 rpm Power Required : 1562 KW Casing Design Temp : 150 0 C Suction Pressure : 10.0 Kg/Cm 2
Motor: KW : 2020 KW Volt : 6600 Volt Rated Amps : 209 amps Rpm : 1492 rpm Insulation Class : F Bearing Type : Tapered Roller
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7.1.5 Schematic Diagram of Gas Booster Compressor
Figure 7.1: Gas Booster Compressor Cooling Water System
Figure 7.2: Gas Booster Compressor Lube Oil System
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Figure 7.3: Gas Booster Compressor Process Gas System
Figure 7.4: Gas Booster Compressor Bearing Temperature, Vibration & Displacement System
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7.2 Plant Air and Instrument Air
An air compressor is used to produce instrument air, plant air, and nitrogen. Carbon molecular fid (CMF) is used to absorb the carbon related material. Oxygen is also absorbed by CMF. Instrument air is used in different types of pneumatic valve and in journal bearing. Lube (lubricating) oil is used for the operation of journal bearing. As it is a mechanical contact, it cannot be 100% leakage free. So the lube oil can leak out from the bearing. To stop the leaking, instrument air is used as a filling to pressurize the lube oil. This filling is used only at GBC. Since lube oil and instrument air can react with each other, nitrogen is used as a barrier to hinder the reaction. Nitrogen is also used inside different pipes when the operation at the plant remains turned off for a long time. This is used to stop the corrosion of the pipe.
7.3 Water Treatment Plant
Water treatment plant is necessary to make it useful for the plant. Here water is used for cooling. Mineralized water is not directly used in the plant. It is full of different minerals, anions and cations. If the mineralized water is used, it will react with metal, which is not desired. At the water treatment plant, the water from the river Shitalakhya is treated. First the anions and cations are removed and then make the water is de-mineralized by reverse osmosis process. Reverse osmosis is a process that various industry uses to clean water. Different types of motor and pumps are used in this process. The driving force of the reverse osmosis process is applied pressure.
7.4 Lubricating Oil Pumps Lubrication to the bearing header is supplied by three lube pumps: The main lube supply pump is a positive displacement type pump mounted in and driven by the accessory gear. The auxiliary lube supply pump is a submerged centrifugal pump driven by an A.C motor. The emergency lube supply pump is a submerged centrifugal pump driven by a D.C motor. 7.4.1 Main Lube Pump
The main lube pump is built into the inboard wall of the lower half casing of the accessory gear. A splinted quill shaft drives it from the lower drive gear. The output pressure to the lubrication system is limited by a back-pressure valve to maintain system pressure.
7.4.2 Auxiliary Lube Oil Pump
The auxiliary lube pump is a submerged centrifugal type pump driven by an A.C. motor. It provides lubricant pressure during start-up and shut-down of the gas turbine when the main
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pump cannot supply sufficient pressure for safe operation.
7.4.3 Emergency Lube Oil Pump
The emergency lube pump is a D.C., motor-driven pump, of the submerged centrifugal type. This pump supplies lube oil to the main bearing header during an emergency shutdown in the event the auxiliary pump has been forced out of service because of loss of A.C. power, or for other reasons.
7.4.4 Mist Eliminator
The main function of mist eliminator is to remove the oil vapor and to maintain the negative pressure at the tank to avoid the pressurization of tank and preventing the lube oil leakage from tank. The lube comes along with the vapor is filtered and diverted back to tank and oil vapor is thrown out to the atmosphere. Normally tank pressure is to be maintained around 50 mmwc below the atmospheric pressure.
Figure 7.5: Mist Eliminator
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7.5 Start Up Sequence
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7.6 Shut Down Sequence
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7.7 Schematic Diagram of Overall Control System Used in Siddhirganj 2X120 MW Peaking Power Plant
Figure 7.5: Timers & Counters Control System
Figure 7.6: Wheelspace Temperature Control System
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Figure 7.7: Bearing Temperature Control System
Figure 7.8: Vibration Control System
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Figure 7.9: DLN (Dry Low NOx) Control System
Figure 7.10: Flame Control System
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Figure 7.11: Exhaust Control System
Figure 7.12: Synchronization Control System
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Figure 7.13: IGV (Inlet Guide Vane) Control System
Figure 7.14: Startup Control System
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Figure 7.15: Central Control Room of Siddhirganj 2120 MW Peaking Power Plant
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7.8 SPEEDTRONIC MARK-VI Control System The Top block in the diagram is the interface data processor called < I >. It includes monitor, key board and printer. Its main functions are driving the operator displays, managing the alarm process and handling operator commands. < I > also does the system configuration and down loaded, off-line diagnostics for maintenance, and implements interface to remote operator stations and plant distributed control systems.
The common data processor < C > collects the data for display, maintains the alarm buffers, generates and keeps diagnostic data, and implements common I/O for non critical signals and control actions Turbine supervisory sensors such as wheel space thermocouples come directly to < C >. The < I > processor communicates with < C > using peer-to-peer communication link which permits one or more < I > processors. < C > gathers data from control processors by participating on voting link.
At the core of SPEEDTRONIC Mark-V control are three identical processors called < R >, < S >, < T >. All critical control algorithms, turbine sequencing and primary protective functions are handled by these processors. They also gathers data and generates most of the alarms.
An independent protective module < P > is internally triple redundant. It accepts speed sensors, flame detectors and potential transformer inputs to perform emergency electronic over speed, flame detection and synchronizing functions. The hardware voting for < P > solenoid outputs is accomplished on a trip card associated with the module. The trip card merges trip contact signals from the emergency over speed, the main control processors, manual trip push buttons and other hard wired customer trips.
Over speed and synchronization functions are independently performed In both triple redundant control and triple-redundant protective hardware, which reduces the probability of machine over speed or out of phase synchronization to the lowest availability values.
7.8.1 Common Terminology used in Gas Turbine Logics
7.9 Daily Log Sheet of Siddhirganj 2120 MW Peaking Power Plant
Figure 7.16: Daily Log Sheet
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7.10 Daily Generation Report of Siddhirganj 2120 MW Peaking Power Plant
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7.11 Palnt Thermal Efficiency& Other Data of Siddhirganj 2120 MW Peaking Power Plant
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CHAPTER 08 CONCLUSION
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8.1 My Achievements
Before the internship, I had learned many theories and working principles of power system and related equipments in relative academic courses. However from the internship I acquired practical knowledge about power system engineering and its equipments. I always tried to relate what I saw at the power plant to my academic courses. My communication skills also improved through communicating with different mentors. Most importantly I have gathered practical experience on how electricity is generated. Therefore, I believe I made good achievements with my industrial training which will help me a lot in my future.
8.2 Problems Faced
There were some problems which I faced during the internship period. The problems are given below:
During the course of my internship, due to low gas pressure, I was never able to observe full load of the power plant. I would have liked to learn more thoroughly about all the sections at the power plant but was unable to do so due to the short length of the internship period. I had very little academic knowledge about the mechanical sections of a power plant.
8.3 Recommendations
There were some recommendations which I want to suggest -
The exhaust gas coming out through the chimney has a temperature of 543 C. This exhaust gas pollutes the environment. I suggest them by extracting the heat energy from the exhaust gas and recycle it for other purpose.
During my industrial training period, I saw that the plant tripped several times. I asked the Shift Engr. about the reasons. He told me that the main reason is temperature of journal bearing of gas booster compressor is increase and vibration of generator shaft is increase. I suggest them for proper maintenance of journal bearing of gas booster compressor and shaft of generator.
Sometime I saw that some engineers avoid some sensors alarm. So that the plant may have a big problem. So I suggested them that to take care of sensors alarm. So that there will be no possibility of big problem.
They havent sufficient engineers in maintenance section. If more faults occurred at a time, power generation will interrupted for a long time which makes loss for the company.
SUPPLEMENTARY PART
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Appendix
A Active Power: The product of the voltage across a branch of an alternating-current circuit and the component of the electric current that in phase with the voltage. Air Compressors: An air compressor or a gas compressor operates on the simple principle of taking in a quantity of air or a certain gas and increasing its pressure many times over by reducing its volume. Ampere (amp): A unit used to define the rate of flow of electricity (current) in a circuit; units are one coulomb (6.28 x 10 18 electronics) per second. Apparent Power: The product of the root-mean-square voltage and the root-mean-square current delivered in an alternating-current circuit, no account being taken of the phase difference between voltage and current. Auxiliary Transformer: Local distribution transformer used for the local electrical supply of the diesel power plant B Breather: Silica gel placement on the transformer Bus-bar: The metal (often copper) bar system which is the distribution media for the 3-phase high voltage system in the power plant .
C Capacitor: An electric circuit element used to store charge temporarily, consisting in general of two metallic plates separated and insulated from each other by a dielectric. Circuit Breaker: An automatic switch that stops the flow of electric current in a suddenly overloaded or otherwise abnormally stressed electric circuit. Current: The rate of flow of electricity. The unit of the ampere (A) defined as 1 ampere = 1 coulomb per second. Current Transformer: In electrical engineering, a current transformer (CT) is used for measurement of electric currents. Current transformers are also known as instrument transformers.
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D DC: Direct current; an electric current flowing in one direction only and substantially constant in value.
E Electromotive Force (emf): The potential difference between the two electrodes in a cell. The cell emf is the cell voltage measured when no current is flowing through the cell. Exciter Current: The field current required producing rated voltage at rated load and frequency. Exciter Voltage: The voltage required to cause exciter current to flow through a field winding.
F Frequency: Number of cycles over a specified time period over which an event occurs. G Generator: A device that produces electric current, usually by rotating a conductor in a magnetic field, thereby generating current through electromagnetic induction. I Isolator: A passive attenuator in which the loss in one direction is much greater than that in the opposite direction; a ferrite isolator for waveguides is an example. K Kilowatt Hour (KWh): 1000 watt hours. KVA: Kilovolt Amperes (1000 volt-ampere) L Load: The electrical demand of a process expressed as power (watts), current (amps) or resistance (ohms). Lightning Surge: A transient disturbance in an electric circuit due to lightning P Phase: A time based relationship between a periodic function and a reference. In electricity, it is expressed in angular degrees to describe the voltage or current relationship of two alternating waveforms.
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Potential Transformer: An instrument transformer whose primary winding is connected in parallel with a circuit in which the voltage is to be measured or controlled and it also known as potential transformer. Power Factor: The extent to which the voltage zero differs from the current zero. (p.f = kW / kVA)
R Relay: An electromechanical device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other. Resistance: The resistance to the flow of electric current measured in ohms (1/2) for a conductor. Resistance is function of diameter, resistivity (an intrinsic property of the material) and length. Rotor: A rotor is a rotating body whose journals are supported by bearings. Relay: An electromechanical device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other. S Stator: The portion of an electrical machine which contains the stationary parts of the magnetic circuit and their windings. Synchronization: Refer to the way in which a power generating source is connected to another at the exact point in time when they both have the same frequency, voltage and period. T Transformer: A device used to transfer electrical energy from one circuit to another. With an alternating current, a transformer will either raise or lower the voltage V Voltage: An electrical potential which can be measured in volts. Voltage Regulation: The difference between maximum and minimum steady state voltage divided by the nominal voltage expressed as a percent of the nominal voltage.
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Acronyms
A Ampere AC Alternating Current ACB Air Circuit Breaker ACDB Alternating Current Distribution AVR Automatic Voltage Regulator BOP Balance of Plants BPDB Bangladesh Power Development Board CT Current Transformer DC Direct Current DLN Dry Low NOx EDG Emergency Diesel Generator EGCB Electricity Generation Company of Bangladesh EMF Electromotive Force FSNL Full Speed No Load GBC Gas Booster Compressor GT Gas Turbine GTG Gas Turbine Generator GTMCC Gas Turbine Motor Control Circuit Hz Hertz Hp Horse Power HT High Tension I/C Incomer IGV Inlet Guide Vane KA Kilo Ampere KVA Kilo Volt Ampere KW Kilo Watt LT Low Tension MCB Miniature Circuit Breaker MCCB Molded Case Circuit Breaker MVUAS Medium Voltage Unit Auxiliary Station MVUAT Medium Voltage Unit Auxiliary Transformer
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NC Normally Closed NGR Neutral Grounding Resistance NGT Neutral Grounding Transformer NO Normally Open OFAF Oil Forced Air Forced ONAF Oil Natural Air Forced ONAN Oil Natural Air Natural O&M Operation and Maintenance PPP Peaking Power Plant PMCC Protection of Motor Control Circuit PMG Permanent Magnet Generator PT Potential Transformer PFI Power Factor Improvement RPM Revolution per Minute SA Surging Arrestor SAT Station Auxiliary Transformer SF6 Sulfur Hexafluoride SSB Station Switch Board SWYD Switch Yard UAT Unit Auxiliary Transformer V Volt VCB Vacuum Circuit Breaker
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Work Cited Books: Gas Turbine Manual Frame 9E PG-9171E Operation Manual of Siddhirganj 2120 MW Peaking Power Plant G. R. Nagpal, Power Plant Engineering, Khanna Publishers, Fifteenth Edition 2006 Sunil S. Rao, Switchgear Protection and Power Systems, Khanna Publishers, Twelfth Edition 2007 V. K. Mehta, Rohit Mehta, Principle of Power System, S Chand & Company Ltd, Fourth Edition 2008
Websites: www.egcb.com.bd www.wikipedia.org/wiki/Electrical_substation www.wikipedia.org/wiki/Transformer www.wikipedia.org/wiki/Switchgear www.wikipedia.org/wiki/Circuit_breaker www.answers.com/topic/circuit-breaker www.wikipedia.org/wiki/Relay http://emadrlc.blogspot.com/2013/01/chapter-1-introduction-to-gas-turbines.html http://www.techtransfer.com/resources/wiki/entry/2563/ http://www.electrical4u.com/protection-system-in-power-system/ http://www.electrical4u.com/electrical-power-transformer-definition-and-types-of- transformer/ http://www.electrical4u.com/voltage-transformer-or-potential-transformer-theory/ http://www.electrical4u.com/current-transformer-ct-class-ratio-error-phase-angle- error-in-current-transformer Pictures taken at Siddhirganj 2120 MW Peaking Power Plant Materials provided by the mentors at Siddhirganj 2120 MW Peaking Power Plant