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GAS PLANT
FAMILIARISATION
3. Fuel System 12
Introduction
The development of the sector in the country, since independence has been
predominantly through the State Electricity Boards. In order to supplement the
effects of the states in accelerating power development and to promote power
development on a regional basis to enable the optimum utilisation of energy
resources, the Government of India decided to take up a programme of
establishment of large hydro and thermal power stations in the central sector on
a regional basis. With this in view, the Government set up the National Thermal
Power Corporation Ltd., in November 1975 with the objective of planning,
construction, commissioning, operation and maintenance of Super Thermal and
Gas Based Power projects in the country.
The availability of gas in a large quantity in western offshore region has opened
an opportunity to use the gas for power generation, which is an economical way
and quicker method of augmenting power generating capacity by natural gas as
fuel in combined cycle power plant in a power deficit country like ours. With this
intention in mind the Government has asked NTPC to take up the construction of
Kawas, Auraiya, Anta, Dadri and Gandhar Gas Power Project along the HBJ Gas
pipe line.
The power plant will consist of gas turbine generating units waste heat recovery
boilers, steam turbo generator, ancillary electrical and mechanical equipments.
The power generated at this power station will be fed over 220 KV AC
transmission system associated with this project to distribute the power in the
various Regions.
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In the Power Sector, the use of gas turbine drive generators has just started and
will go a long way in meeting the countrys requirements.
Gas turbines range in size from less than 100 KW up to about 140.000 KW. The
gas turbine has found increasing application due to the following potential
advantages over competive equipment.
Combined Cycle
Combined Cycle power plant integrates two power conversion cycles namely.
Brayton Cycle Gas Turbines) and Rankin Cycle (Conventional steam power
plant) with the principal objective of increasing overall plant efficiency.
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Brayton Cycle
In the actual process losses do occur. Deviation from the theoretical process,
results from the fact that compression and expansion are not performed
isentropically but polytropically which is conditioned by heat dissipation
(expansion) and heat supply (Compression) caused by various flow and fraction
by losses.
In the combined cycle mode, the Brayton Cycle is chosen as the topping cycle
due to the high temperature of the exhaust of the gas turbine (point 4 in the P.V
diagram). In modern gas turbines the temperature of the exhaust gas is in the
range of 500 to 550oC.
Reference to the T.S. diagram may indicate the amount of heat that is produced,
converted into mechanical energy and extracted from this process. For the
evaluation of the cyclic process, two parameters are of greatest importance;
Thermal efficiency is obtained from chemical binding energy of the fuel and
mechanical energy available at the shaft of the gas turbine. Thermal efficiency
(th) as follows:
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th = Energy at GT shaft
Chemical Energy of fuel
Working capacity is also obtained from the difference between the amounts of
heat supplied and removed. This is achieved by increasing P2 that is increasing
gas inlet temperature T3.
BRAYTON CYCLE
FIG-1
Rankine Cycle
The conversion of heat energy to mechanical energy with the aid of steam is
carried out through this cycle. In its simplest form the cycle works as follows
(fig.2).
The initial state of the working fluid is water (point-3) which, at a certain
temperature is compressed by a pump (process 3-4) and fed to the boiler. In the
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boiler the compressed water is heated at constant pressure (process 4-5-6-1).
Modern steam power plants have steam temperature in the range of 500oC to
550oC at the inlet of the turbine.
COMBINE CYCLE
FIG-2
We have seen in the above two cycles that gas turbine exhaust is at a
temperature of 500 550oC and in Rankine Cycle heat is required to generate
steam at the temperature of 500-550oC. so, why not use the gas-turbine exhaust
to generate steam in the Rankine cycle and save the fuel required to heat the
water ? Combined Cycle does just the same.
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The efficiency of Gas Turbine cycle alone is 30% and the efficiency of Rankine
Cycle is 35%. The overall efficiency of combined cycle comes to 48%.
It is basically of two types, namely Unfired Combined cycle and Fully Fired
combined cycle.
The basic system is shown in figure- 3. in this system the exhaust gas is used
only for raising steam to be fed to the steam turbine for power generation.
The conventional fossil fuel fired boiler of the steam power plant is replaced with
a Heat Recovery Steam Generator (HRSG). Exhaust gas from the gas turbine is
led to the HRSG where heat of exhaust gas is utilised to produce steam at
desired parameters as required by the steam turbine.
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However, non-reheat steam turbine is the preferred choice for adopting this type
of system as usually the live steam temperature for HRSG will be solely
controlled by the gas turbine exhaust temperature which is usually around 500oC.
In recent development, with the introduction of Dual Pressure Cycles more heat
is recovered in the HRSG and steam with higher pressure and temperature can
be generated. But higher capital investment and sometimes necessity of
supplemental firing system makes the system complex and costly.
Fig 4 shows the basic schematic of this cycle. In this system the heat of
exhaust gas from gas turbine is used for two purposes as described below:
Gas turbine exhaust contains about 14 to 16 % oxygen (by weight) and can be
used as hot secondary air in the conventional fossil fired furnaces. So the heat
required to heat the secondary air will be saved and can be used for other
purposes. FD fan power consumption will also be reduced to a great extent.
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BOILER REPOWERING SYSTEM EXHAUST HEAT EXCHANGER
Fig 4
Fuels
Gas turbines are capable of burning a range of fuels including naptha, distillates,
crude oils and natural gas. Selection of fuel (s) depends on several factors
including fuel availability, fuel cost and cleanliness of fuel.
Natural gas is an ideal fuel because it provides high thermal efficiency and
reliability with a low operation and maintenance cost. Liquid fuels, particularly
heavy oils, usually contain contaminants, which cause corrosion and fouling in
the gas turbine. Contaminants, which cannot be removed from the fuel, may
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leave deposits in the gas turbine, which reduce performance and add
maintenance costs.
Dual fuel systems are commonly used, enabling the gas turbine to burn back-up
fuels when the primary fuel source is not available. Dual fuel systems can also be
designed to fire both fuels simultaneously.
Apart from the higher overall efficiency, the combined cycle power plants have
following advantages:
Low installation Cost: power from a combined cycle power plant is approximately
70% of a conventional coal based power plant of same capacity.
Low Gestation Period: Power from a combined cycle power plant can be
obtained in two phases, i.e. two third power, obtainable from gas turbines, is
available within 16-18 months and the balance in next 1 month. This is much
lower than the gestation period for conventional thermal power plants, which is
around 48-60 months.
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2. Gas Turbine Starting System
The function of the starting system is to crank the gas turbine upto the required
speed until : it becomes self sustaining.
One method of starting large gas turbine is by using a motor driven hydraulic
starting system. Alternatively, the GTG can be started by using a frequency
converter to rotate the generator which drives the turbine for starting.
A typical hydraulic starting system for each gas turbine consist of the following:
Auxiliary Gear
Couplings
The electric starting motor drives the hydraulic torque generator through a
coupling. The hydraulic torque converter consists of an impeller, which forces the
fluid against hydraulic starting motor. The hydraulic torque converter is coupled
to the accessory gear, which is connected to the gas turbine shaft. The torque
converter receives hydraulic fluid from hydraulic and lube oil reservoir during
operation. When gas turbine reaches self-sustaining speed the starting device is
disconnected and shut down. To break the inertia of the starting motor and
reduce the starting current a pony motor is provided. Gas turbines of GE and WH
designs are provided with starting motor system for cranking purpose.
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The static frequency converter serves the same function of starting, accelerating
running at preset speed by starting the generator as a synchronous motor by
feeding variable frequency current drawn from the connected grid. Gas turbines
of ABB and SIEMENS make are provided with frequency converter s for the GT
cranking and normally 2 * 100% static converters are provided for the power
station.
To start a gas turbine in the event of AC-power failure an emergency black start
system is provided. It also helps in safe coasting down of the gas turbine and its
auxiliaries following a trip in the event of grid collapse. The black start system
consist of a separate diesel engine or a gas turbine driven synchronous
generator connected to station switch gear bus. It can be operated manually from
local or remote and also it automatically comes into operation following a black
out condition. Capacity of the black start unit should be such that it can supply
the total auxiliary power required to start a gas turbine from standstill condition.
The NTPCs Auraiya project gas turbine is provided for emergency black-start
purpose and all other projects are provided with diesel generator set for the same
duty.
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3. Fuel System
The function of the fuel system is to deliver fuel to the combustion chamber(s) of
a gas turbine at quantity and pressure as required by the control system
The liquid fuel system consists of the liquid fuel storage and handling system.
The liquid fuel storage and handling system provides means for unloading ,
storage and distribution of the fuel oil within the plant and typically composed of
the following major components:
The number and size of equipments is site dependant. The storage facility is
dependant on such factors as the location of the site, proximity of the oil supply
and the reliability of the oil supply. Fuel oil may be supplied to the plant by a
pipeline, oil barriages, oil tankers, rail/road or high way trucks. Fuel oil unloading
pumps may not be required if the oil arrives by a pipeline, an oil barge, or an oil
tanker since they have their own pumps.
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Naphtha Pressurising System
By the forwarding pumps,Naptha is pumped upto the GTs and kept under
recirculation. For firing the naphtha is the GT,separate pressurising system with
high pressure pump, allied filters and measurements and recirculation system is
used. This pressurising is required because in the naphtha burner this fuel is
mechanically atomised. There is no other medium like air, etc are used for
atomisation.
Since the flash/fire point of this fuel is very low it is designed to drain the oil from
the piping burner etc when the system is stopped. Separate drain tanks are kept
at pumping stations, which will collect these naphtha and pump back to the main
storage tanks.
Mode of firing
It is provided to fire natural gas or naphtha or in mixed mode of the fuel in the GT
Combustion Chamber.
The purpose of the fuel gas system is to take gas fuel from the custody transfer
point, process it to the quality and pressure conditions required by the gas
turbine and to distribute it and monitor its use. Fuel gas system consists of the off
base system and the on base system.
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Off base fuel gas System
The off-base fuel gas system is typically composed of the following major
components:
An emergency stop valve at the gas inlet to the plant knock out drum
Filters
Pressure-control station
Distribution piping
The need for any of the optional components is dictated by the conditions
specific to each individual application. The final supply pressure required at gas
turbine is a function of the gas turbine compression ratio and the control valve
and nozzle pressure drops. Large gas turbines typically require a gas supply
pressure of about Kg/cm2 with pressure regulated with in +10 percent of set
point.
The emergency stop valve at the in let to the station is provided to completely
shut off the gas supply in an emergency. The gas fuel then goes through a
knockout drum. A knock out drum will remove the free liquid and some solids
from the gas stream. However, it will not separate out much of the entrained
liquids. The liquids separation from gas stream takes place by decreasing the
gas velocity in its transit through the drum. Impurities collect at the drum bottom
and are periodically automatically purged A level controller opens a drain valve
which allows the waste to Adrian tank vented to the atmosphere.
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The filter separators must have minimum of two stages of separation. The initial
stage being utilised for removal of large liquid droplets and the final stage for
mist separation . Any solid particles carried with the gas stream are separated
in the first stage . The first stage elements consist of hollow tubes of glass
fibers through which gas flows radially from outside. The separation of carried
solids and liquid particles is by interception, diffusion and/or inertial impaction of
the droplets on the fibers. The liquid droplets coalesced on the surface drain on
to the shell and from there to the drain pot. The second stage mist separator is
preferably of the vans type in which liquid separation takes place by subjecting
the gas path to multiple changes of direction.
The gas analysis is carefully checked from the stand point these point of hydrate
formation or icing at the pressure reducing station under the worst ambient
temperatures prevalent at each site. If there is any tendency for the above, a
suitably, rated gas fired indirect heater is provided ahead of the pressure
reducing station. The gas heater ensures a gas temperature sufficiently high
such that the after pressure reduction the gas temperature is at least 20 C
higher than hydrate forming temperature or the gas dew point whichever is
higher. The heater normally utilises natural gas for firing. Heat from the fire tube
be utilised to heat a water bath in which the U tubes for carrying the gases to be
heated are immersed. The control system ensures constant temperature of the
outlet gas for gas flows ranging from zero to full gas flow. A full capacity bypass
is provided so as to enable operation of the fuel gas system is designed to
deliver gas fuel to the gas turbine combustion chamber(s) at the proper pressure
and flow rates to meet all the starting, acceleration and loading requirements of
gas turbine operation.
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Naphtha forwarding system
The forwarding system is mainly remote controlled from the GT LCR and CCR.
Although there is a possibility to control the main devices locally by a switching
the selector switch on local position in the local panel.
By means of three way valves a tank selection is possible. To ensure the standby
position of the lines keep the value open. The pumps are protected by the
automatic recirculating valves. The condition of the strainers as well as of the
filters is monitored by the differential pressure indicators and switches. The
safety valves protect the line against the line against over pressure.
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4. Fire Detection And Protection System
The combined cycle power station represents a large capital investment in high
technology plant and equipment, the loss of which would entail disruption to the
power system and a larger reduction revenue. It is necessary to protect this
investment against fire damage and to this effect an elaborate fire detection and
protection system is being provided throughout the power plant.
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The various fire detection and protection system are :
Hydrant System
The high pressure water spray system applies water in the form of a conical
spray consisting of droplets of water travelling at high velocity. The automatic
operation of flow control/deluge valve can be through wet Detection or Dry
detection-Initiation System.
Separate 2x100% capacity pumps and header is provided for H.V.W. spray
system.
This system is provided to protect transformer and gas reducing station (for
indoor installations) and lub oil storage tanks.
The medium velocity water system applies water in finely divided droplets
travelling at medium velocity to control the fire and the same time renders
adjacent areas safe by cooling action. This system is operated manually and
protect tanks containing flammable/combustible liquid such as Naptha. The
discharge density shall not be less than 10.2 litres per minutes per sq. metre.
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Sprinkler System
The sprinkler system consists of a pipe work array filled with water having
sprinkler needs at laid down intervals which operates at a predetermined
temperature. Conventional cable galleries are not provided in the combined cycle
power plant, however the spreader rooms where power cable are is protected by
sprinkler system.
Halon System
In NTPCs earlier gas project, automatic inert gas extinguishing system using
Halon 1301 was used to protect electrical and electronic equipments. However,
recent scientific researches have indicated that man chemicals such as Halon
and Chlorofluorocarbon deplete stratospheric ozone layer. In view of adverse
Environmental impact, NTPC has stopped using Halon flooding as well as Halon
extinguishers for all future projects.
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CO2 Extinguishing System
After deflected of halon extinguishing system for all future NTPC projects,
modular CO2 extinguishing system is envisaged in control panels, fuel gas
control block of Gas turbine (under sound proof enclosure), GT sound proof
enclosure, bearing housing within exhaust diffuser and the cable space below
electronic equipment room. This system is designed to achieve 34%
concentration by volume in the areas to be protected and are equipped with
optical type and ionisation type smoke detectors. Temperatures detectors are
installed in the bearing housing within exhaust diffuser.
iv) The system is on modular basis and can be expanded at a later date.
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v) The interface units are provided for connecting open type alarm initiating
devices such as pressure switches, potentials free contracts etc.
vi) Exact location of fire can be known from the fire alarm control panel.
Potable Extinguishers
Portable pressurised water type and CO2 type extinguishers are provided at
strategic locations inside the entire power station area. For 600 MW combines
cycle power plant, approx. 75 nos. water type and 100nos. of CO2 type portable
extinguishers are provided.
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5. Salient Features Of NTPC Gas Projects
The plant is located near Anta Town of District Kota in Rajasthan. The
nearest railway station is that of Anta which is approximately 1 km.from
plant site. The branch offline of HBJ pipeline is approximately 15 kms.from
the site, from where a tap offline is taken. The Kota right main canal which
is the source of plant water requirements, runs along the plant boundary.
In the main plant block, the gas-turbines and the steam-turbine are
housed in separate buildings. There are 3 GTs in are one hall and one ST
in another building, with GT hall towards the west. In the extension stage
of the project, the mirror image of stage I is anticipated and after
completion it shall have 2 GT, halls with 3 GTs on each side of the ST hall
having 2 STs. The extension is planned towards the east of stage I. The
GTs are placed transversally. The control building is adjacent to ST
building. Each GT is having one local control centre located towards south
of GT hall. The transformer yard is towards south of turbine hall and
switchyard is further south.
The plant is located near village Kawas in District Surat of Gujarat. The
nearest railway station is that of Surat which is approximately 19 kms.
From site.
In the main plant block two modules each consisting of 2 GTs and ST
have been provided. The turbine building houses two pairs of GTs at the
east and west ends with 2 ST in the middle. Here all GTs and STs are
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placed longitudinally. The common control building is located adjacent to
the ST hall towards north.
Each WHRB is located towards south of the respective gas turbine. Each
GTG is having one local control room which is located towards north,
below the inlet air filter. The transformer yards is in north of turbine hall
and switch yard further north.
The plant is located in Etawah District of Uttar Pradesh. The plant site is
approximately 2.5 kms. from the nearest railway station of phaphund.
In the main plant block, two no of STGs are located in between 2 pairs of
GTs. GTGs are placed transversally. The central control room with 220 KV
switchyard control room is located close to STG-I. Local control panel of
each GTS is located near the GT pedestal itself.
The water pre-treatment plant and DM plant are located adjacent to both
the power house and CW pump house.
Induced draft cooling towers have been located considering the proper
flow of cooling water, nearness to main power house & convenient routing
of open return channel to CW pump house. The 200/400 KV switchyard
has been located in front of the power station.
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D DADRI GBCCPP-STAGE I (817MW)
In the main plant block two modules, each consisting of two GTGs placed
on each side of 2 STGs. The central control room is located towards west
of the ST hall. The transformer yard Is on the western side of the turbine
hall, with switchyard further down west.
Induced draft cooling towers have been located considering the proper
flow of cooling water. Nearer to main power house & convenient routing of
open return channel to CW pump house. The 220/400 KV switchyard has
been located in front of the power station.
The GAIL terminal for receiving gas is located within boundary of plant
site.
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6. The Modern Large Size Gas Turbine, Type
GTI3
The main feature of this gas turbine is the simple design, one compressor, one
combustion chamber with one burner, a 5- stage turbine arranged on a common
shaft with the 17- stage compressor, the shaft being mounted on two journal
bearings, the axial thrust absorbed by one thrust bearing as well as an exhaust
gas diffuser which permits an easy connection to a waste heat boiler.
With the increasing operational experience the coupling output of this type could
be considerably raised by gradually increasing the gas turbine inlet, temperature.
This was made possible by cooling the blades of the 1st and 2nd stationary and
rotating blade rows or total, with the typical gas turbine, by
cooling the first three stages and by an intensified cooling of the rotor and the
gas turbine blade carrier.
The positive results expected by these measures such as higher power, higher
efficiency and lower specific cost have been fully confirmed by the experience
gained in operation.
The single combustion chamber was mounted at the side of the gas turbine, and,
via a U-shaped double piping, connected to the gas turbine. In the course of the
further development of this type it was possible, in spite of the higher gas turbine
inlet temperature, to reduce the size of the combustion chamber so that it is now
arranged directly above the gas turbine. A dual fuel burner makes it possible,
simultaneously or alternately, to use gaseous or liquid fuels at improved
combustion conditions.
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The separation of flow surging, during partial speeds, may be prevented also with
the aid of several adjustable stationary blade rows. Today,, economic reflections
lead to the blow off solution or to combined system with blade readjustment and
blow off facilities in the case of industrial gas turbines.
A typical intake & exhaust system for an industrial gas turbine, comprise the
following components:
The need for filtration on gas turbine inlet arises because of four phenomena:
foreign object damage erosion, fouling and corrosion.
Foreign object damage is usually defined as the resultant blade damage caused
by the ingestion of an object of suitable mass and hardness to create physical
destruction.
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Erosion is typically defined as the actual removal of material by collision with a
moving object. It is often observed on the compressor blades of a gas turbine
due to the exposure to larger sized contaminant particles.
Corrosion is the loss of material in the hot sections due to chemical reaction. It is
typically observed in off shore and near shore environments and is attributable to
small salt practices and heavy metals.
No Filtration
In the early days of stationary turbine application, it was widely believed that inlet
filtration was not needed, that the turbine could ingest almost anything as long as
it was not a large object. Many early units were only provided with a simple
screen on the inlet to prevent entry of animals, birds, and any other large object.
Moving Media
The first major problem undertaken was to deal with the larger particles which
caused erosion of the compressor blades. By experience and past history, it is
generally accepted that a 10 micro metre particle is a size of sufficient mass and
inertia to cause actual removal of the metal in a compressor blade. Two of the
earliest designs selected were the roll-type and the travelling screen filters.
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The roll-type filter utilizes a roll of dry viscous treated filter material inserted at the
top, fed down through a passageway to take-up reel on the bottom.
This material is advanced either on demand via the increasing pressure drop
across it or automatically on a time basis.
The travelling screen filter utilizes an endless belt of metal elements which
passes through a through of viscous oil, removing the accumulated contaminants
and replenishing the viscous treatment. The visors treatment itself is the medium
for tapping the airborne particle. The travelling screen type has many of the same
operating parameters as the roll-type (efficiency, pressure drop) with one unique
potential disadvantage, that of oil carry-over contamination.
Both the roll-type with viscous impingement and the travelling screen type
depend upon one primary mechanism to trap the airborne contaminants, an oily
surface to which the particle will adhere. If the oil is not present or has been
covered over with particles, the removal efficiency will drop off markedly.
Both of these types have been used throughout the world with limited success.
Today they are both basically obsolete.
Inertial Separators
Both use the principle of accelerating the particle and using its own inertia to
remove it from the main air stream.
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The primary advantage with an inertial separator is its low maintenance cost and
relatively trouble free operation, making it very suitable for remote locations. The
need for a secondary power source for the scavenge blower is occasionally a
disadvantage, however, the restriction across the inertial separator does not
increase with operating time and remains constant under normal conditions. The
inertial separator does have proven quite successful in terms of dealing with the
larger particles and have gone a long way in reducing significantly the typical
erosion problem with turbines. One major shortcoming has been in areas of
extremely heavy dust conditions such as desert where the percentage of
particles that do pass the inertial separator can still be harmful.
The majority of high efficiency media filters in use today are composed of
randomly oriented small filters, either of cellulose or a synthetic material.
Such filters depend upon the contaminant particle contacting a fiber by one or a
combination of three mechanisms: Inertia Impaction, Interception and Diffusion.
Multi-Stage Filters
While the high efficiency filters do an excellent job of protecting the turbine, they
typically have a rather low dust holding capacity and are subject to frequent
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servicing. The solution to this has been to use some form of filtration ahead of
the high efficiency filter to extend its useful life.
In multistage filters a number of different concepts have been applied. All operate
on the basic principle of having one or more stages of some type of device ahead
of the high efficiency filter elements to help extend the useful life of the high
efficiency elements.
Self-Cleaning Filters
The high efficiency filter cartridges are attached to the bottom of a horizontal
plate and hang vertically downward: Above each filter cartridge, in the clean air
plenum, is a venture flow nozzle. During normal operation, ambient air flows
upward, radically inward through the cartridges and then upward through the
venture and finally to the turbine. Up to this point the device is operating basically
as just a high efficiency filter. Each cartridge is rated for 500-600 cfm at an initial
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pressure drop of 1.2-1.8 inches of water, hence the total number of cartridges
required for any installation is controlled by this operating range. Skirts are
suspended around the exposed sides of the cartridges to protect them from
damage and to force the incoming air to travel upward.
A pressure switch senses that this upper limit has been reached and activates
the timer/sequencer. The timer/sequencer signals the solenoid value to open,
releasing the pressure holding the pneumatic air valve. The release of the air
valve (typically for only 50-100 milliseconds) allows a blast of compressed air
(80-100 psig) to leave the air manifold and proceed out through the blow pipe.
Above each venture is an outlet hole in the blowpipe. This blast of compressed
air exist through the hole, enters the venturi, induces a secondary flow into the
venturi and effectively closes off the flow through the cartridge for a fraction of a
second. The compressed air pressure wave continues down into the cartridge
and then radically outward, blowing the accumulated dust off the cartridge. In
another fraction of second, the cartridge is back in service. A row of cartridges is
pulsed at one time. Then 10-20 seconds later the timer/sequencer chooses
another row of cartridges and the Pulse-Cleaning procedure is repeated. The
timer/sequences continues to sequence the cleaning operation through out the
elements until the overall pressure drop reaches a preset lower limit, at which
time the cleaning process ceases until called upon again by a high-pressure drop
reading. The number of elements cleaned at any instant and the time interval
between are chosen so that no significant distortion of the airflow is presented to
the turbine.
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Since the pulse-cleaning filter renews it self as needed, the old concept of how
much dust a filter can hold no longer applies. The system will maintain the
average pressure within its upper and lower limits virtually independently of the
ambient dust concentration.
American air filter company has introduced an augmented self cleaning air
filtration system (ASC) In which self-cleaning principle is combined with inertial
separation, and the separated dust is taken out from the operational area by an
exhaust system.
Dust laden air enters the ASC intake system and is cleaned by passing through
the panel pack filter elements with in the housing. The clean filtered air exit
through the ventures in to the clean air plenum and on to the turbine in take.
However, by means of the integral secondary air cleaning circuit about 75% by
weight of the dust is removed from the incoming air by inertial separation before
it reached the panel pack filter elements.
The inertial separated dust together with a small amount of scavenge air is
conveyed into the secondary cleaning air circuit where the secondary air fan
exhausts air fan exhausts it to the atmosphere at any desired point of discharge.
The reverse air cleaning cycle is controlled by a solid state printed circuit timer
which is housed in a control panel assembly. The timer sequentially energizes
the solenoid valves that activate air valves to admit sharp bursts of compressed
air through vertical blowpipes located in the clean air plenum. Orifices located in
the blowpipes direct the compressed air horizontally through the ventures into the
filter chamber. The momentary pressurization and reversal of air flow dislodges
the accumulated particulate from the filter elements, automatically reconditioning
the filter for continued uninterrupted services. The dislodged dust is immediately
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sucked into the secondary cleaning air circuit together with the scavenge air. In
this manner there is no re entrainment of the dislodged dust back into the filter
elements.
Entrance to the secondary air circuit is through a strategically located slot at the
apex of the V formed by two adjoining panel pack filter elements. This
secondary air slot leads into a vertical metal secondary air duct that conveys the
particulate to a horizontal dust chute and exhaust fan.
Pulse-Cleaning Filters
Silencer
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sheeting. If the surface of absorption material is covered with an impermeable
layer of dirt, the effectiveness of the silencer reduces. Thus the draw back of
these type of silencers is their susceptibility to soiling.
In gas turbine inlet and exhaust system adsorption silencers with splitter or baffle
type arrangement are provided. To optimise pressure drop, and to attenuate
noise levels over a range of frequency baffle/splitter are arranged in staggered
form. Normally baffles are made of perforated stainless sheets filled with mineral
wool felts and pads.
The GT engine, by its very nature, requires a considerable mass flow of air per
KW delivered than other conventional engines. Thus, the duct sizes will be
larger, if conventional power plant criteria for ducts, gas velocities are used. Of
course smaller duct sizes require higher velocities & resulting greater pressure
loss. Design consideration or pressure loss. Design considerations or pressure
loss influences depends on Fluid dynamic and geometric consideration.
The detailed producers for calculation of pressure loss in inlet and exhaust
system is not presented here & standard literature on the subject may be referred
in case it is required.
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Normally, when a GT unit is supplied on a turnkey basis, GT manufacture
optimises the pressure loss in the inlet & exhaust system to maximize output &
heat rate of the engine. However, in case GT inlet & exhaust system are ordered
are ordered separately, the GT manufacturer specifies corresponding maximum
losses in inlet & exhaust system respectively, at which output & heat rate of the
machine are guaranteed. Accordingly allowable pressure drop in the dusting
system is decided, taking into account pressure losses in other system
components.
COMBUSTION CHAMBER
Introduction
In the combustion chamber the air delivered and compressed by the compressor
is brought to the necessary process temperature by the combustion of liquid fuel
(e.g. fuel oil) and/or gaseous fuel (e.g. natural gas). The simple combustion
chamber is vertically arranged on the thermal block. Cooling air required for
cooling of the hot gas turbine parts is bypassed.
Design Features
PMI,NTPC 35
GAS TURBINE UNIT
Fig . 5
Owing to the high thermal stresses of these parts, a special design and carefully
selected material are required to ensure a long operating life. They have proven
very successful for a long time. The finned segments (bricks) made of a highly
heat resistant material are, on the fire side, connected by a cladding and
protected from the hot flame.
PMI,NTPC 36
FINNED SEGMENTS
figure. 6
Convective cooling of the finned segments is carried out on the rear side but
cooling air flowing between the ribs, and open the fire side by a cooling air film
which escapes on from the bottom side on the end of the bricks and is passed
over the row located beneath. The finned segments can be easily replaced with
the aid of a special lifting device.
The upper combustion chamber inert consist of the outside unit and the double-
wall interior unit is made of heat-resistant sheet metal welded together.
For the observation of the combustion zone during operation, several sight glass
units are mounted on the combustion chamber. Moreover, there is an automatic
flame monitoring devices on the combustion chamber cover. The whole
PMI,NTPC 37
combustion chamber is fitted with a thermal- acoust insulation and encapsulated
with galvanized sheet steel.
1. Burner
- A burner for the gas turbine in Contrast to gas turbines with many
combustion chamber, no measure for an accurate distribution of
fuel and air are required to obtain a good temperature distribution.
- Standard burner for oil and/or natural gas, consequently suited also
for mixed operation.
- The burner itself can be removed and checked which ensures easy
maintenance.
- The design ensure a good ensures a good atomising of the fuel and
consequently, optimum evaporation and mixing with the air which is
PMI,NTPC 38
essential to good combustion. The combustion efficiency amounts
to > 99.58, under full load > 99.98.
- Since there is only one fuel jet, it has relatively larger openings so
that it is less prone to contamination.
- One ignition for the whole system easier, i.e. higher ignore on
reliability than with multiple combustion chamber systems.
Combustion Space
No flame contact with the wall, which means that no combustion takes
places near the wall and, consequently, the film cooling air cannot be
misused as combustion air (this danger exists with small size chamber
chambers).
Thus the flame tube does not consist of one ring, but is formed by
individual elements. Therefore, no stability problems (dents) of the
combustion wall as is the case with flame tubes.
Long dwell time ensure burning out of the fuel (the emission of CO and
non-burnt hydrocarbons is practically zero).
PMI,NTPC 39
Flame radiation independent of the fuel since E of the flame (desire of
emission) is nearly 1.0 (black body).
COMBUSTION CHAMBER
Fig.7
PMI,NTPC 40
Burner Combustion
The dual burner with its auxiliary facilities is used for the supply of gaseous and
liquid fuels to the combustion chamber. Simultaneously, mixing of the fuel with
the primary air is achieved with this burner, while the flame is stabilized by an
appropriate air supply.
c) Combustion
The air arriving from the compressor enters the combustion chamber from
the bottom and flows upwards. Approximately 30% of the air between
combustion chamber outer jacket and other part of the lower combustion
chamber liner flow as secondary air via the mixing jets to the combustion
chamber inner space while the remainder flows further upwards between
inner and outer part. Further distribution takes places at the funnel shaped
outlet of the lower combustion chamber outlet.
Via an orifice on the lower end of the intermediate jacket another 30% of
the air are branched off for cooling the finned segments. This air then is
PMI,NTPC 41
dispersed on the partition walls and flows between the cooling ribs
downwards into the combustion space, while a layer of protective cooling
air is formed on the flame side of the ribs which protects the ribbed bodies
from adverse heating.
The remaining 40% flow as primary air i.e. as oxidizing agent for the
combustion, into the swirl insert in the air enters the combustion space in
a turbulent state. This ensures a very good mixing with the fuel. Moreover,
the swirl insert is used for a good stabilization of the flame.
Another portion of the primary air flows through four orifices in the gas
burner jacket into the annuls between inner jacket and inner wall of the
gas burner jacket and enters the combustion space directly at the fuel
nozzle with a turbulence caused by the inner swirl insert. By this type of air
guide a very intensive mixing with the fuel is attained which ensures a
complete and rapid combustion. The ignition of the fuels during starting is
effected by the igniter with a propane flame.
PMI,NTPC 42
After ignition of the fuel, the hot combustion gases flow downwards. Before they
enter the turbine, these gases are well mixed with the secondary air, coming from
the mixing orifices and brought of a temperature admissible for the turbine.
The air enters with swirl to the combustion space through the primary air inlet
(swirl insert). Due to this flow scheme (cyclone principle), a back flow to the
burner jet is produced. This reduces the flame front speed, which ensures a
stable flame. The cyclone effect is terminated by the inflowing cooling air at the
mixing orifices (D).
Fig-10 shows a fuel jet liquid fuel is injected at a very high pressure and finely
atomized.
PMI,NTPC 43
FIG-10
TURBINE
In the gas turbine, the power for driving both the compressor and the generator
is produced. The energy is supplied to the turbine in the form of the hot gases as
they come from the combustion chamber. The kinetic energy of the gases is
transferred to the rotor in the turbine by means of the rotating blades. In the
following this process is explained with the example of a gas turbine stage.
The combustion gases, coming from the combustion chamber or from the
preceding stage, are accelerated in the stator blade to the speed C while,
PMI,NTPC 44
simultaneously, the inlet pressure is reduced. By vectorial addition with the
circumferential speed the relative speed w is obtained.
TURBINE BLADES
FIG.-11
PT = PV+PN = mR. ht .
PMI,NTPC 45
ht = Isentropic turbine gradient in kj / kg
= effective efficiency, e = it . m
P2 = 1 bar t2 = 490oC
Hu = 42000kj/kg
PN = PT - PV = 212.5-124.5=88.0MW.
DESIGN FEATURES
Talking into account its thermal load the turbine housing made of creep-resistant
ferrite mater raise as welded structure or steel casting. On the exhaust gas side
the inner cone of the turbine housing is connected to the outer wall by ribs.
Inner cone and outer wall form in this area the annuals for the escaping exhaust
gas. Because of the relatively high exhaust gas temperatures the walls and ribs
of this duct in the gas turbine housing are cladding with a sheet metal lining. The
PMI,NTPC 46
sheet metal lining is made of a temperature resistant material and fastened in
the turbine outer housing allowing for thermal motion. The bearing housing
made of cast steel for the reception of the journal bearing on the exhaust gas
side is suspended allowing for thermal motion in the inner cone of the outer
housing bottom part.
The stationary blade carrier made of alloyed ferrite cast steel is cooled with the
aid of compressor air which enters through appropriate holes and air inlets.
To keep the thermal flux and the temperature stresses in the stationary blade
carrier(fig.12) low also during start-up and shutdown of the machine the side
exposed to hot gas is provided with heat shields which are radically suspended.
BLADE CARRIER
Fig-12
The turbine blading consists of five stationary and five rotating blades. Because
of the continuously increasing turbine inlet temperature the number of cooled
PMI,NTPC 47
stages is increased(from a stage at the beginning with 13D2stages on 13D2to
3stages on the 13Etype).
BLADE COOLING
Fig-13
In convection cooling air flows through holes smooth or ribbed ducts (figure 14)
and absorbs part of the quantity of heat transferred by the hot gas into the
blades. Depending on the design, the heated cooling air is mixed to the hot gas
on the blade trailing edge, on the blade tip and or an the blade.
PMI,NTPC 48
GUIDE VANE CONNECTING COOLING Fig-14
DEFLECTOR COOLING- which also called jet cooling is also type of convection
cooling. However, the cooling air is passed through the sheet metal deflector
plates. These deflector inserts are provided with holes so that the cooling air
bounces as jets on the blade wall to be cooled.
PMI,NTPC 49
7. Gas Turbine Compressor
General
The characteristic feature of this turbine generator set is the use of a single,
composite welded shaft for the compressor and turbine gas rotor, carried in only
two bearings. This enables the complete compressor/turbine assembly to be of
very compact construction and ensures good shaft stability with a simple bearing
arrangement of two journal bearings and one thrust bearing.
The welded rotor concept has been in use for many years in the steam turbine
field and this design has also proved superior for the gas turbine. In comparison
to a rotor comprising several disc held together by a tie rod. The welded rotor has
several important advantages: the welded discs have o holes in highly stressed
areas, especially in the center, and dangerous stress concentrations are
therefore avoided. The welding joins the discs together into a single shaft without
mechanical joins in which misalignments caused by centrifugal force or thermal
expansion cannot occur. This is particularly important with large shafts. The
commonly- observed heavy vibrations caused by rapid acceleration and load
application are completely avoided. The welded designs avoids all the problems
which can otherwise occur due to the above- mentioned mechanical joins. In
addition, this design guarantees maintenance free service of the rotor.
The compressor and turbine casing consist of several sections which are joined
together to form a single unit.
PMI,NTPC 50
Air Intake connection
The air intake connection has a horizontal air inlet, and is situated axially in front
compressor. It is a welded, solid steel plate construction split horizontally and
held together with hexagon bolts and nuts. The attachment to the compressor
casing is effected by two guide flanges welded on to the connection which locate
in the appropriate slots turned in the compressor casing. Sealing tubes made of
synthetic material are laid in these slots and form a seal against the environment.
The air intake connection has four feet which are bolted with adjusting belts to
steel plates embedded in the foundations. These bolts allows the height to be
adjusted to that of the rest of the compressor/turbine assembly.
Compressor casing
The upper and lower halves of the compressor casing are provided with robust
flags and are held together by expansion studs with sockets head nuts.
To bearing housing for the intake end journal bearing and thrust bearing is
integrally cast with the help of the compressor casing. The bearing cover
is bolted on to the bearing housing. The oil glass for the thrust bearing and the
axial shaft position monitor are mounted on the. The flanges of the bearing cover
and housing are sealed with an oil resistant jointing
The bearing cover and housing incorporate all the necessary grilling for lube oil
purpose, for the sealing air of the intake end shaft seal and for temperature
monitoring.
PMI,NTPC 51
The lower half of the compressor casing is also fitted with paws for the fixed
supports at the intake end and for the pin-ended supports at the pressure end, as
well as the flange for the king pin which is situated at the intake end and
determines the fixed point form the complete compressor/turbine assembly.
The compressor casing has three integrally- cast circular ducts, which are
connected to the blade duct behind the fourth, seventh, and tenth rows of fixed
blades. These ducts are closed to the outside by four blow-off values flanged
directly to the upper half of the compressor casing. the blow-off values are
controlled pneumatically and are open at lower speeds,i.e.up to approx 90%of
the rated speed, so that a certain amount of the compressor output can be blown
off. the air blown off flows into the machine room through the blow-off valve
bonnet arranged around the valves and a silencers in that order. these blow-off
valves enable a consideration reduction to be made in the external power input
requirements during start-up, and they also avoid undesirable and dangerous
flow conditions in the compressor which result in rotating stall and pumping
effects.
The outer casing is split into two halves the same as the compressor casing. the
turbine and compressor casing are bolted together at a radial flange with
expansion bolt. the casing parts are centered by means of eight round wedges in
the circumference.
The turbine casing is made of heat-resisting ferrite steel in order to withstand the
thermal stresses, and is of welded construction. the upper and lower halves are
bolted together at the horizontal flanges with expansion studs, expansion sleeves
and socket head nuts. The horizontal flanges are of solid construction and are
slotted at the drilled holes so as to avoid high thermal stresses. Horizontal and
radial flanges of the turbine and compressor are metal-to- metal joints.
PMI,NTPC 52
The inner cone and outer wall of the turbine casing are joined together by ten ribs
at the exhaust end, and the resulting ring duct between the two constitutes the
flow passage for the exhaust gas from the turbine. Due to the relatively exhaust
gas temperature, the walls and ribs of the ring duct are lined with a special
plating to prevent the temperature differences between various parts of the
casing walls and therefore, the thermals stresses during transitional operating
phase (e.g. starting up and shutting down); from exceeding the allowable limits.
The planting is manufactured from temperature resistant materials and is
attached to the turbine outer casing in such a way as to accommodate thermal
expansion.
A cast steel bearing housing is mounted in the inner cone of the lower half of the
outer casing and provides the support for the exhaust end journal bearing. The
housing is free to thermally expand. The bearing housing is retained in the
turbine outer casing by means of integrally cast guide at axis height and by a key
collar bolts are provided to prevent lifting.
The reaction forces of the journal bearing are transmitted through the lower half
of the inner cone and the above-mentioned ribs to the turbine outer casing. From
here are transmitted through the pin-ended supports to the unit support.
The trip and mechanism for the two over speed trips, which are mounted at the
rotor are installed on the bearing housing. The oil supply line mounted on a cover
on the hearing housing enables the over speed trips to be checked while the
turbine is operating by supplying oil pressure to the underside of the over speed
bolts. Ventilation and oil wiper rings are inserted in the bearing cover and bearing
housing and also in the intake end bearing housing and cover to prevent the
escape of oil. Two air deflector plates are welded in to the lower half of the outer
casing to stabilize the flow. In addition two paws are cast integrally with the lower
half of the turbine outer casing, and the pin-ended supports of the exhaust end
are bolted to these paws.
PMI,NTPC 53
The vertically arranged combustion chamber is mounted on a horizontal flange
welded on to the upper half of the outer casing. In addition, the outer casing has
a circumferential coller for the blade carrier.
Blade carrier
The blade carrier for the turbine fixed blade is a ferrite steel alloy casting and is
axially spilt the same as the compressor/turbine casing. It is bolted together with
expansion bolts, expansion sleeves and hexagon socket head nuts. The blade
carrier is fluxed axially by a collar in the turbine outer casing, which fits in to a salt
around the blade carrier circumference. Paws are integrally cast with the parting
flange of the lower half of the blade carrier at the same level as the outer
circumferential salt. These paws have hardened pads fixed to them and together
with the corresponding support surfaces in the turbine outer casing they form the
vertical support for the blade carrier. An axial salt, is machined in the lower half of
the blade carrier at the same level as the circumferential slot , and the guide pin
fitted in the lower half of the turbine outer casing locates in this axial slot hold the
blade carrier in its lateral position. The external pressure of the compressed
combustion air on the blade carrier causes it to be pressed against the support
collar and forms a metal-to-metal seal to the exhaust end. This air also cools the
blade carrier at the same time. A more intensive cooling of the blade carrier is
achieved by allowing a small amount of air to flow through the appropriate holes
and circular ducts. This air flow results fro the relatively small differential pressure
between the compressor exhaust and turbine Intel and is sufficient to maintain
the temperatures within the allowable limits. This air stream reenters the hot gas
flow channel before the first row of fixed blades.
Radically supported heat storage segments are fitted between the rows of fixed
blades in the areas exposed to the gas flow, similar to the heat shield of the
turbine end of the rotor. These segments contain the heat flow and thermal
stresses within the blade carrier at a low level during start-up and shut-down.
PMI,NTPC 54
Owing the absence of centrifugal stresses these segments can be mounted in
the blade carrier more simply than on the rotor.
The cooling air deflectors fitted to the upper half of the blade carrier are to
improve the cooling of the corresponding inner casing walls.
The combined compressor and turbine rotor comprises the individual discs which
are welder together to form the compressor and turbine blading. The eleven
discs constituting the body of the shaft are centralized with one another by
circumferential recesses and connected together by a special welding process.
The complete shaft comprises seven compressor discs, and a center drum
connecting the two section made of a ferritic forged steel alloy. The end discs
have forged journals, and the one at the compressor end is fitted with a coupling
flange and thrust bearing caller. The complete shaft is stress-relieved after
welding. The blade rotor is then over speeded to 20% above the rated speed and
balanced.
The compressor turbine rotor is carried by two journal bearings which are
force-lubricated and cooled. The bearings are each held by four fitted plates and
are each prevented from rotating by a solid pin. The bearing are lined with white
metal and the radial clearance is approx 1.5%. A lubricating oil film is formed by
the pressurized oil, which enters the bearing from both ends and is forced in to
two lube oil groves. The lower halves of the journal bearing are connected to
jacking oil pumps which deliver high pressure oil to the bearing to lift the
compressor- turbine rotor from the lower shells thereby reducing the initial
breakaway torque.
PMI,NTPC 55
COMPRESSOR TURBINE ASSEMBLY
Fig-16
The axial thrust of the rotor is taken up by the thrust bearing situated at the
compressor end. This bearing is of the pad type and is also lubricated and cooled
by pressurized oil. Since the thrust on the turbine balding is in opposition to that
compressor balding the resulting differential axial thrust remains small. Moreover,
this thrust always acts in the same direction, i.e. against the gas flow and
PMI,NTPC 56
towards the generator. The thrust bearing also fixes the axial position of the rotor
in the casing. Both expand in the same direction since the fixed point is given by
the king pin for the complete casing and is situated in the area of the thrust
bearing. A shaft monitor is provide which measures the axial displacement. This
gives an alarm in the event of abnormal displacement and then gives a trip
signals for the unit when a maximum value is reached. The axial clearance
required can be adjusted at the bearings.
The surface of the rotor between the rows of turbine blades is protected against
excessively high temperatures by heat storages segments. These subdivided the
hot upper surface of the rotor into small rectangular zones. They can expand
freely in all directions independently of the exhaust end of the shaft. In this way
the major part of the heat which enters the rotor from outside is conducted away
just below the surface of the rotor, so that the amount of heat reaches the actual
body of the shaft remains small. This results in a relatively slow warm-up of the
shaft body and therefore high thermal stresses cannot occur. A similar effect is
experienced during shutting down when the flame is extinguished and a relatively
cold air stream flows through the machine while it slows down. The lifespan of
the rotor is extremely good with this method or construction.
The cooling air required for the turbine part of the rotor, the feet of the turbine
rotor blades and the first and second rows or rotor blades is taken directly from
the compressor flow at the diffuser after the last row of fixed blades. The air flows
through the channels between the compressor diffuser and the shaft cover to a
ring nozzle, and then to the turbine part of the rotor. Here it passes through
drilling in the projecting shoulder of the rotor and flows through the cooling air
ducting system between shaft and heat storage segments and also around the
blade feet.
After the fourth rotor blade row the cooling air exhausts into the gas steam from
the rotor. It then flows over the feet of the last row of rotor blades and leaves with
PMI,NTPC 57
the exhaust gases. Part of this cooling air flow is used to cool the rotor blades in
the first and second rows. The cooling air flow is monitored by measuring the
pressure difference across the ring nozzle of the nozzle of the compressor
diffuser. The sealing air for the shaft seal cools the end of the rotor at the
exhaust end. Shaft seals are formed by thin sheet metal strips caulked into
grooves in the rotor by means of caulking wire, operating at a small running
clearance with either the shaft seal shell or the corresponding part of the casing,
respectively relatively few sealing strips are required to give an adequate seal
since the pressure difference at the shaft seal is small. The exhaust end shaft
seals prevent the gas from escaping to atmosphere. Those at the intake end
prevent the ingress of oil laden or otherwise contaminated air from the bearing
regions into the flow duct/ both these shaft seals have a sealing air supply taken
from the blow off duct after the fourth row of fixed blades in the compressor. At
the exhaust end draft seal the sealing air supply comes through the shaft seal
shell, thus cooling the rotor end as well as explained above. The shaft seal at the
air intake end is divided into two groups of sealing strips. Here the sealing air
enters the annular space between two groups via the appropriate ducts and
holes in the compressor casing. The shaft seals situated between the
compressor and turbine prevent the leakage of too much cooling air.
Pressure tapping are located before and after the sealing strips of the shaft seal
directly below the first row of turbine fixed blades. These are used to measure
the pressure difference, which is necessary to monitor the correct functioning of
the shaft sealing.
Compressor balding
PMI,NTPC 58
They are either precision forged or machined, and fit into slots which are turned
in the shaft and compressor casing. The blades are separated from one another
by spacers. The blades of the first seven rows are rooted directly in the shaft,
those of the remaining rows are inserted in intermediate pieces.
Turbine Blading
The turbine blading is also of the reaction type, and consists of five rotor and five
fixed rows of blades. Due to the high temperature of the incoming gas, the first
and second rows of the rotor and fixed blading are cooled with air from the
compressor.
The cooling air is fed to the first and second rows of fixed blades through holes
drilled in the blade carrier and to the first and second rows of rotor blades
through drilling in the shaft and through the passage underneath the heat storage
segments. After entering the blade foot, the air passes along several parallel
ducts into the blade proper. Each air stream changes direction several times
inside the blades in the first and second fixed blade rows and before finally
blowing out through a number of slits in the trailing edge of the blade.
Part of the cooling air in the first row of rotor blades and the second row of fixed
blades and the entire cooling air flow in the second row of rotor blades is blown
out through the blade tips. The first row of fixed blades is film- cooled as well,
whereby the air leaves the blades through numerous small holes and forms a
protective film over the blades surface. This method of cooling ensures that the
leading and trailing edges of the blades in particular are thoroughly cooled,
thereby avoiding cracks induced by thermal stresses.
These cooled blades and the fixed and rotor blades of the other rows are
precision cast in a nickel based alloy. The fourth and fifth rows of rotor blades
and the fifth row of fixed blades are precision drop-forged.
PMI,NTPC 59
The first row of fixed blades sits in an axial slot in the carrier segments, which are
in turn fitted into a slot in the blade carrier. The specially-formed ends of these
blades are supported in the shroud segments which are mounted in a radial slot
in the compressor diffuser, which extends as far as this point.
The remaining fixed blades have rhombic shaped feet which fit into the
appropriate slots of the blades carrier.
The first row of rotor blades are fitted into radial double. T slots in the rotor
while the fifth row fits into angled fir tree slots.
The so-called super materials: and high alloy steels used in the turbine blading
are all resistant to extremely high temperatures and to scale. Their anticipated
service life is calculated on the respective prevailing temperature and resulting
stresses. An additional protective measure has been taken to counteract
corrosion in the form of a specially applied chrome layer on the first rows of
blade. This increases the service life of the blades considerably.
Compressor Diffuser
The main function compressor diffuser is that of flow device, namely reducing
the relatively high velocity of the combustion air from the compressor blading
while keeping losses to a minimum, and ensuring a favorable flow into the turbine
outer casing and combustion chamber connection.
The compressor diffuser is branched into a radial and an axial section, so giving
a favourable flow distribution which produces uniformly intensive cooling of the
entire inner casing surface. The shaft cover and the inner shell of the compressor
diffuser together form the annular duct for the cooling air for the turbine section of
the rotor. The nozzle segments are fitted in circumferential slots in the diffuser at
the outlet of this annular duct. These nozzle direct the cooling air flow with
PMI,NTPC 60
minimum losses to the rotor. At the inlet to the turbine blading, the end shroud
segments of the first row of fixed blades and the inlet segments together form a
heat shield for the wall of the compressor diffuser. Both segment types are
inserted in circumferential slots in the compressor diffuser.
The compressor diffuser and the shaft cover are heat resistant spheroid graphite
iron castings. They are both splits horizontally, the same as the rest of the
casings in the compressor/turbine assembly. The top and bottom section of the
compressor diffuser are bolted together at the parting flange with expansion
bolts.
The complete compressor diffuser is flanged at the front end to the lower half
only of the compressor casing, and is cantered by a collar on the front flange
which fits into a corresponding recess turned in the compressor casing.
Inner Casing
The inner casing guides the hot gases coming from the combustion chamber to
the turbine blading. It is a relatively thin walled welled construction made of heat
resistant chrome nickel austenitic alloy. The outside of the inner casing is cooled
by the combustion air coming from the compressor diffuser. It rests on supports
in the turbine outer casing is split axially, and is held together by expansion bolts
made of high temperature resistant materials. All flanges bolts of the inner casing
are secured by special locking devices so that they cannot become loose during
operation.
The inner casing is supported by two flange rings at its outlet which fit into
corresponding recesses turned in the blade carrier and compressor diffuser. This
prevents axial movement and at the same time guarantee good separation
between the hot gas and compressed combustion air in the turbine casing. A
drain connection is arranged in the lower half of the inner casing which is used
PMI,NTPC 61
for draining fuel which has not burnt due to ignition failure (only with oil or dual
fuel operation). Special equipment and the associated guide bolts must be used
when fitting or removing the inner casing, and the instructions must be followed
implicitly.
Exhaust Diffuser
The exhaust diffuser is a single unit of welded steel plate construction to the
turbine outer casing by two radial flanges forming metal to metal joints, and
guides the relatively hot exhaust gases into the exhaust gas system. Expansion
bolts with hexagon head nuts are used to bolt the diffuser to the turbine outer
casing. The inner part of the exhaust diffuser, which is annular in shape, is
essentially held by three oval- shaped, hollow plate ribs. These serve at the
same time to permit access to the diffuser up the exhaust end bearing, for the
installation of pipe- work, and also for ventilation purposes. The sheet metal
cover of the thermal installation on the inside of the diffuser is welded over a third
of its circumference to make it oil tight and so prevent smouldering which might
occur as a result of oil leakage. A leakage drain is fitted to the lowest point of the
diffuser unit.
A traveling hoist can be fitted to one of the rails inside the exhaust diffuser and
this assists in the assembly and disassembly of the exhaust end bearing during
erection and overhauls so that bearing parts can be lifted in and out through the
upper hollow rib. The exhaust diffuser is supported on the foundations through
two adjustable spring supports. These take up small relative movements
between the exhaust gas system, exhaust gas diffuser, and machine
foundations.
PMI,NTPC 62
Support
The casing rests on two fixed supports at the intake end between which is a solid
king pin which fixes the position of the compressor/turbine assembly laterally and
longitudinally.
The king pin, which is situated below the machine in line with the central axis,
takes up the forces which are transmitted by the exhaust gas system.
Longitudinal movement of the compressor/turbine assembly is guided by the
guide key below the turbine flange.
Insulation
The exhaust gas diffuser is thermally insulated and soundproofed with the
special insulating material consisting of several layers. This is covered with the
galvanized steel sheet. Insulation of the air intake connection is similar to the
exhaust gas diffuser. The enclosure over the compressor/turbine assembly, ie.
the gas turbine unit, is free-standing on the machine foundation and can be
PMI,NTPC 63
walked on for access purposes. It reduces the noise level and protects the
insulation from damage. It also improves the appearance of the unit.
Compressor Section
Compressors for gas turbines may be centrifugal or axial flow type, but all large
gas turbine use axial flow compressors. Gas turbine compressors are multistage
design and consists of individual discs or wheels mounted on a shaft. Each disc
holds the compressor blades which extend rapidly. This complete assembly is
called the compressor rotor and is enclosed in the compressing casing. The
casing holds stationary blades which direct the air flow against the rotating
blades. The stationary assembly is called the stators. As the blades force air
through the compressor, the casing area decreases and air is compressed
through each successive stage.
Early axial compressor designs were almost all based upon constant axial
velocity over the length of the compressor. This constraint simplified some flow
analysis and together with other arbitrary assumptions such as constant inner
diameter or constant diameter enables analytical and design team to cope with a
complex engineering problem. The large investment made in such design
approaches has resulted in their persistence in present day gas turbines. Over
time, the body of
PMI,NTPC 64
gas turbine compressor design is fixed for a particular machine by the
manufacturer. It is not an option to be selected; rather it is part of an overall piece
of equipment. The compressor must be designed and operated so as to avoid
compressor surge. The surge characteristic of compressor is a complex function
of many compressor design features. It can also be affected by compressor
deterioration and blade fouling in operating units. In order to avoid compressor
surge, each stage of the compressor must maintain its overall flow situation.
When a breakdown of this overall flow situation occurs in any one stage, the
result is usually disruptive to the flow situation in subsequent stages and surge
occurs. Under such conditions, intermittent flow and conditions such as puffing
or rotating stall(in which only a part of one ore more stages is in surge while the
remainder is in steady flow ) can occur . In such conditions are found to occur at
rotational speeds high enough to pose the danger of mechanical damage to the
combustion turbine unit, the situation can be alleviated by :1) providing inter
stage relief valves at one or more points along the compressor or 2) equipping
or more stages of is based on years of research and development and the
compressor stationary blade rings with variable geometry provisions. The first
method maintains a viable axial velocity distribution by relieving axes flow from
the later stages of the compressor . The second method controls the flow
produced by the variable geometry stages to be within the capacity of the later
stages of the compressor.
The method of surge control is inherent to the design of each particular gas
turbine and is left to the manufacturer.
In large industrial type gas turbine, two types of combustion chambers are used.
With an annular type combustors, combustion occurs in numerous combustion
chambers located radially around the compressor discharge casing. Some
manufacturers use a single or dual silo type combustor, which is a large
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chamber, mounted on top of the turbine. Each combustion chamber includes fuel
nozzles, and ignition system and flame detectors. Each combustor is enclosed in
a casing and liner for support and insulation. Compressor discharge bleed air is
used to cool the combustor.
Turbine Section
The turbine expands the hot gases from the compressor and combustor and
drives the compressor and generator. The turbine is constructed similar to the
compressor. Turbines are multistage design and consist of individual discs or
wheel mounted on a shaft. Each disc holds the turbine blades (buckets), which
extend radially from the shaft. This complete assembly is called the turbine rotor
and is closed in the casing. The casing holds stationary nozzles, which direct the
gas, flow against the turbine blades causing the rotor to rotate.
Generator Assignment
The generator can be located either at the hot and (exhaust) or the cold
end(inlet) of the gas turbine. With a hot end generator, the exhaust system
becomes more complicated and direct axial exhaust into the HRSG is not
possible with a hot end arrangement. Using a cold end generator arrangement
may complicate the air inlet system. It may also complicate arrangement of the
starting drive and/or accessory gear. Either arrangement is acceptable and the
location is the manufacturers choice based on his experience.
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8. Waste Heat Recovery Boiler
INTRODUCTION
The utilization of the wastes heat recovery system in combine cycle power plants
with gas turbines is a relatively recent development brought by the development
in the field of gas turbines resulting in gas turbines becoming larger in size and
output, the large volume of heat available form gas turbine exhaust and rising
fuel costs.
One of the main features of the gas turbine is the high mass flow of air used over
the stoichiometric quantity of air. Typically volume of [excess air factor] for gas
turbine combustion lies between 3 to 4. this means there is more than sufficient
oxygen to support secondary combustion, if required. This high mass flow in turn
makes the gas turbine exhaust an ideal candidate for heat recovery steam
generation.
Description
The basic wastes heat recovery boiler (WHRB) consists of an evaporator which
is the basic steam generator, and an economizer which heats the incoming feed
water to the evaporator. Super heaters are also furnished, and condensate
preheaters (low pressure feed water heaters/ are sometimes used depending on
need and circumstances.)
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A complete wastes heat recovery boiler would also include an inlet gas by-pass
damper, with by pass stack and silencer, exhaust stack with monitoring
provisions and all interconnecting ducting between the gas turbine and exhaust
stack. Other WHRB accessories include the drum level sight glasses and level
controls, pressure gauges, continuous blow down control and sampling stations.
The economizer is a feed water heater operating at the steam drum pressure
utilizing the heat left in the exhaust gas after the gas leaves the evaporator. The
economizer will heat the incoming feed water to the evaporator
Super heaters are basically steam heater receiving saturated steam from the
steam drum and producing superheated steam. Super heater are located ahead
of the evaporator in the WHRB exhaust gas flow stream in order to develop
required superheated steam temperatures.
Low pressure feed water heaters also called condensate perheaters are
sometimes used on combined cycle units to heat the desecrator feed water thus
the cycle required less desecration steam making it more efficient.
WHRB exhaust gas by pass are commonly provided to isolate the WHRB form
its heated source. If furnished this isolation will permit running the gas turbine at
times whens steam is not required or when WHRB is not available. Normally the
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by pass dampers will have a straight open/close function though some designs
can also provide degree of modulation. A by pass stack complete with silencer is
required and provided when by-pass dampers are used
Duct burners can be used to raise the temperature of the exhaust gas to produce
more steam. However, duct burners are generally not used on combined cycle
plants due to the low rankine cycle efficiency as compared to higher combined
cycle efficiency.
Design considerations
The general design philosophy of the WHRB is to exhaust heat form the
gas to the fluid at the highest temperature difference available. This can
best be accomplished by making the gas and the fluid [steam or water]
temperature gradients as nearly parallel to each other as possible. With a
single pressure level boiler, the choice is very limited since the super
heater, evaporator and economizer have to be placed in descending fluid
temperature along the gas path, in a multi pressure level unit this general
order is maintained, but various section may be interchanged so that a
nearly parallel relation between the temperature gradients can be
achieved.
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However each successive pressure level adds to the plant cost and
complexity, which may make them uneconomical for most combine cycle
applications. Due to this reason dual pressure WHRBs are commonly
used particularly in combined cycle application where moderate and low
pressure steam is required. Dual pressure WHRBs are basically two
WHRBs utilizing the same gas stream. The high pressure section of the
WHRB would consist of an HP evaporator complete with HP economizer
and HP super heater interconnected to produce HP superheated steam.
The major advantage a bypass damper and stack can offer are
i) To phase out the installation schedule of the GT open cycle and combined
cycle module, and
ii) The capability of running the G when the GT open cycle and obtained
cycle module, and generator is out of service for scheduled maintenance
or repair.
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In the case of the steam turbine down, it is possible to run a GT without a bypass
stack if the steam can be used elsewhere or dumped. For combined cycle
applications however, the use for the steam else where is generally nonexistent
and dumping the steam involves sizing the condenser to take the full load steam
in a steady state condition, running steam and circulation water cycles in an
unproductive heat-dump mode of operation. Alternatively, the WHRB is required
to be suitable for dry running. A further advantage the bypass damper offers is
the provision to control, to a limited extent, the heat input into the WHRB and the
quantity of steam produced partially bypassing the particularly important and
useful during cold startup operations.
Another distinct advantage of the bypass damper is the ability to isolate the
WHRB from the GT during the initial preoperative GT testing, when the repeated
stop-start operating of the GT can otherwise cause condensation to occur
throughout the WHRB.
Disadvantages in using a bypass duct and damper include the initial equipment
cost, maintenance costs on the bypass dampers and the constant heat loss
through both direct exhaust gas leakage and heat loss through the dampers.
A value can be derived for the GT operating time gain utilizing the bypass on
consideration of the expected WHRB and steam turbine down times which can
be compared to the value of the expected constant heat and gas leakage losses,
maintenance costs, and equipment costs. In summary, however there is no
general position on this subject and the same should be evaluated specifically for
each site conditions.
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Type of dampers
The major choice lies between utilizing a single diverter damper or two isolating
type dampers one for the WHRB duct and one for the bypass stuck. The two
damper concept offers the greater selection of damper types that can be used
but has the disadvantage that should both dampers close at the same time the
ducting would become over pressurized. In turn this necessities the installation of
relief panels or pressure relief type dampers, in addition to the electrical interlock
to prevent such situation. In the event of malfunctioning/ failure of the above
provisions a mechanical linkage system ensures that both the dampers are not
closed at the same time, as a foolproof system.
By pass dampers are prone to high leak rates. losses from the dampers include
both sealing losses through leakage and heat losses through the blade(s).For
combined cycle application involving large gas turbines. Damper types cover a
range including,multi louver type, diverter type and flap type dampers.
The advantages and disadvantages of each type and the suitability for a
particular application very with the application.
The multi louver type damper normally has external linkage actuating all the
louvers simultaneously and is good for regulating flow. However it will not be as
good on sealing as the single blade type damper. Further more, any pressure
differential would tend to force one part of the louver seating open, and would not
assist the sealing. The losses from this damper would therefore be greater and
furthermore, differential expansion on the linkage brings to question the
possibility of linkage binding.
The diverter valve offers the advantage that the duct cannot be closed off and
would be open to either the bypass stack or the WHRB. Sealing is generally
effective and the damper can be appropriately insulated to minimize heat losses.
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Flap damper have the same kind do flap operation and sealing action as the
diverter but are single application operating only as a single isolation type
damper. They offer an advantage on extremely large ducts by utilizing a seating
grid in the damper and breaking the damper into two or more individual flaps of
a smaller easier handled size. Disadvantages would be the pressure drop across
the seating grid. Pressure relief type flap dampers are also available and offer
the advantage of incorporating an over pressure relief flaps and avoiding the
additional costs of adding the relief panels elsewhere in the ducting. Normally
they are associated with multi louver dampers.
Generally the diverter and the louver type dampers can be set to a partially open
position to control heat for or start-up. However the dampers are generally not
suitable for continuous modulation such as load following, due to the size. All the
dampers, of course will utilize either motor drive or hydraulic power for operation.
Seals on the dampers are particularly important. Metal seals utilize the pressure
differential in the duct together with a built in spring action to help seat the thin
flexible metal seals against the seats. Normally the seals are attached to the
flaps and the seat area is built into the fixed frame.
Multi blade dampers have a greater seal footage than other types, and only part
of the seal is helped by the differential pressure. Other parts of the seal must seal
against the differential pressure. Because of this multi blade dampers tend to
have a higher leakage rate than the flap or guillotine type dampers. Sealing
efficiencies of 99.95% should be specified for metal in seals without air sealing.
Dual seals are often provided to obtain a greater sealing efficiency. Air seals use
a fan to create a small positive air pressure to help seal the metal seals.
Efficiencies of 100% should be specified for the seals if air sealing is utilized.
Several factors must be considered when selecting by pass dampers the value of
thermal losses, safety considerations cost and operation and maintenance costs.
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Normally the diverter is preferred for the GT by-pass application, however the
actual losses for each particular application must first be considered.
The particular design and type of damper selected will vary with the application.
For example, if air sealing is used. The cost of supplying the constant air supply
must be considered and compared to the additional sealing savings.
By Pass Stack
Stack construction cost will increase with stack height, due to weight to be
supported, increased wind loads, increased material costs, and increased
handling cost and maintenance costs.
The gain in stack draft will be the theoretical stack draft gain less the stack gas
pressure drop and its value will be obtained from the value of the increased
electrical output from the GTC due to less back- pressure.
A theoretical stack draft effect will be produced for each meter of stack height
due to the difference in the weight of the external air at atmospheric
temperature.
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Stack gas pressure drop will be the friction loss plus the stack exit loss.
Stack diameter will require selection prior to the determination of the pressure
drop. In selecting the stack diameter a velocity between 2,000 to 5,000 ft/min
should be assumed and pressure drops determined accordingly.
The wind load on a stack is a major consideration, and a high stack may often
require a large diameter or other special provisions at the base for stability.
The bypass stack construction could be of fabricated carbon steel [outer shell]
with internal insulation and stainless steel liner. Otherwise it could be made of
stainless steel with external insulation and aluminum/GT cladding. Differential
expansion for the complete system is taken care by provision of an Expansion
joint, normally of flexible [fabric] type. In some design, exhaust side silencer is
located in the by pass stack upstream of the damper.
These are two factors which affect the cost and effectiveness of WHRB. Pinch
point is the differences between the gas temperature leaving the evaporator
section of the system and the saturation temperature corresponding to the steam
pressure in that section.
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As a general rule, lowering the pinch point results in an increase in the total heat
recovered in that section. However, lowering the pinch point will require more
heat exchange surface and a subsequent increase in cost and gas side draft
loss. Multiple computations are required to select the most economical optimum.
Another possible penalty which must be evaluated in lowering . then pinch point
excessively is unstable operation. The very low design pinch point may indicate
more heat recovery but if all other factors are not realized, it may result in poorer
performance when steam production is critical.
Lowering the approach temperature can result in more steam production at that
pressure level as with a lower pinch point, this can only be realized at a higher
cost and same increase in draft loss. Higher approach temperature would result
in design stability. The higher approach temperature would increase the surface
in the evaporator section and assure a higher level of stability. Al low load the
gas turbine exhaust temperature will help drop but mass flow of the gas may not
drop signification depended on type of gas turbine and intent vane range. The
quantity of steam generates in the evaporator will drop. The economizer, will see
nearly the constant gas temperature. Conditions but will have to heat a reduced
fed water flow. The reduction in mass flow of the gas is not great as the reduction
in feed water flow. This could cause steaming and water hammer problem in the
economizer.
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Path of Flow
Fig. 17
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Types of Circulation
Circulation of the water through the evaporator tubes can be forced utilizing
circulation pumps or can be natural utilizing gravity and density difference
between water and steam to obtain circulation. Both types of WHRB s are
common with combined cycle power plants.
Natural circulation boilers must have vertical or inclined to the vertical tubing and
will normally have higher initial costs. Forced circulation WHRB s using a
water/steam drum normally use horizontal tubing pump pressure to circulate the
water/ steam through the evaporator tubes. The advantages with horizontal tube
design is the lower cost of the tube bundles and potential for lower cost of section
renewal if request in later years. However, due to horizontal tube design used
with this type of boilers there will be lack of tolerance. Pressure drops through the
horizontal evaporator tube banks must be balanced and often require restriction
on some of the tubing in order to achieve this balance. This increases the
pressure drop through the system and water tend to separate to separate easily
leading to further problem and minimum velocity through the tubes must be
maintained to avoid this separation. If separation does occur, the bottom of the
tube will have a steam surface and heat transfer through the top of the tube will
not be as effective as heat transfer through the bottom of the tube. The top of the
tube will become hotter, setting up thermal stresses in the tube leading to
sagging and in some cases out right tube failure due to overheating the tube.
Thermal inertia of the forced circulation WHRB is less then the natural circulation
WHRB which facilitates faster loading and unloading of the WHRB. The table
below gives the summary of advantages and disadvantages associated with
each type of design.
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Summary Forced circulation Vs National circulation
As stated gas turbine at high excess air. Hence, the exhaust gases have very
high oxygen content of the order of 16 to 20% which is sufficient to support if any
fuel firing desired in the WHRB or its duct.
A WHRB designed to recover only the heat available in the exhaust gases is
termed as unfired WHRB. Where are heat in the exhaust gases is supplemented
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by firing of additional fuel in the WHRB duct, the WHRB is termed as a fired
WHRB.
It must be recognized that the overall combined cycle plant efficiency will drop
when duct firing due to the fact that Rankine cycle efficiency is lower than then
combined cycle efficiency especially when the steam is used in a relatively low
pressure induction type steam turbine. However the cost of installing a duct
burner is extremely small and other equipment costs are nonexistent. Ducts
burning can be advantageously used in combined cycle units where a need
exists for peaking capacity. For evaluation of duct burner firing for peaking in a
combined cycle value of additional KW produced by the steam turbine should be
compared to the cost of generating the steam. Costs of additional steam turbine
generator capacity should be added, if applicable.
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Condensate pre-heaters are subject to similar low load problems as experienced
by the economizer. The problem is aggravated in the condensate pre-heater,
however by a temperature rise in the exhaust gas at low load as the economizer
will use less heat front the gas with the reduced feed water flow. The
condensate pre-heater will therefore be subject to hotter gas together with
reduced condensate flow which can cause severe steaming and steam hammer
in the heater. In many cases the chosen solution to the condensate pre-heater
low load problems is a planned by-pass of the condensate preheater during the
infrequent low load operations permitting the condensate preheater torn day.
Alternate solutions to this problem, dependent on the excepted frequency of low
load operation would include running a full flow feed through the pre-heater at all
times and dumping the surplus heated water to the condenser.
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9. Gas Turbine Generator
Synchronous Generator
The air cooled generator Type WY 18 L is of simple but robust construction. The
generator and the gas turbine 13D are placed on a common and plain concrete
foundation, with the same center line level for both the gas turbine and the
generator rotor. Therefore, the space below the active part could be used to
house the four cooler sections. The outline drawing shows the principle design
and the main dimensions.
Generator Design
The generator is built in compliance with the latest standards of the IEC, ANSI
and VDE, and is designed to operate continuously at rated load but also it
withstand a wide range of abnormal operating conditions, including short circuits.
The horizontally spilt stator casing of the active part consists of two welded sheet
steel constructions, which are screwed together. Inside the casing sheet, steel
ribs are arranged as guide plates for optimum cooling air distribution to the active
sections. The four identical air recooling elements inserted into the casing below
the active part can be withdrawn horizontally.
The low-loss core segments are punched from silicon alloyed electric sheets.
They are carefully deburred and are given several coats of a heat resistant
varnish which can withstand temperatures much higher than the normal
operating temperature. By this manner, the individual segments are dependably
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insulated from each other, so that even after many years; operations no short
circuits or even hot sports can occur.
After stacking the core segments outside the casing, vibrations and inseased
temperatures are applied when the core is compressed between heavy press-
plates. The press-plates are made of low-loss non-magnetic material and press
by special fingers the whole cross section of the core. The resulting core remain
rigid over its whole length, especially the highly stressed end parts, even if
subjected to varying load conditions or daily multiple starts.
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Stator-Winding Bars and Installation of Bars
The main bar insulation is built up following the Micadur (R) system, which was
developed by BBC and which has been successfully used for many years. In this
system, the bars are continuously wound, in an automatic tape winding machine,
with the required number of layers of mica-coated glass-fabric tape.
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STARTOR SLOT CROSSECTION
Fig.-19
The straight part of each bar is pressed to size, the bars then are dried in an
oven, then they are impregnated in vacuum, by a special epoxy resin, and
hardened in an oven by means of circulating air. The finished insulation complies
with the Insulation Class F specifications of the IEC, ANSI and VDE standards.
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ENDWINDING SUPPORT
FIG-20
Terminals
The winding connections and the terminals are connected by means of flexible
copper strips. The flexible strips absorb possible relative motions between casing
and winding which may be caused by different heating of casing and winding.
Both ends of the terminals have two parallel connecting plates, inside the
generator for connecting of the flexible strips, and outside for the connection to
the bus bars to the star point, respectively.
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Rotor Body
The rotor balances the torque of the gas turbine. It leads the magnetic flux, and
carries the field winding and the necessary parts for conducting the field current.
The rotor body is a single forging of heat-treated alloy steel having very good
mechanical and magnetic properties. After heat treatment, the rotor body is
tested using the most up-to-date methods to ensure that the required properties
have been obtained. As an example, the rotor is subject to ultrasonic testing over
its complete length and cross-section. Therefore, a central bore for testing
purposes is not required.
Longitudinal slots are milled in the two winding zones of the rotor surface to carry
the field winding. The different slot shapes in the pole zone and winding cause
different moments of inertia relative to the direct and the quadrature axis. In order
to achieve uniform bending of the rotating rotor relative to these two axes,
transverse slots are milled in the pole zones. This acts to reduce the amplitude of
the double-frequency flexural vibration in a smooth-running rotor.
The driven shaft end of the rotor is provided with an integrally-forged coupling
flange for connecting the turbine shaft.
At both ends of the rotor are seats for the fans and also journals for the bearings,
the ends of the rotor body are machined to take the retaining rings. The non-
driven shaft ends has a central bore to take the rotor filed current lead, while
radial holes are drilled for the lead studs which connect the rotor leads with the
field winding.
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Rotor Winding
The rotor winding is composed of hollow conductors which carry the excitation
current required to produce the armature field. The conductors are made of
drawn silver containing oxygen-free copper having high-grade properties.
In the active region, the hollow conductors are insulated from each other and
from the rotor iron by Nomex, a polyamide paper, fulfilling class F requirements.
ROTOR WINDING
FIGURE-21
The rotor winding is directly cooled by air howing from both ends of the rotor
through all the conductors. At all the air inlets and outlets, the creepage (leakage)
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paths between the bare copper and the rotor mass are rather long. This ensures
goods dielectric strength of the winding even after long operation time.
The filed current is conducted from the slip rings to the rotor windings by means
of two half-round copper lead bars fitted in the shaft bore. At one end of the lead
bars, connection is made to the slip rings by two leads studs and flexible-plate
connectors. At the other end, connection is made to the rotor winding by similar
lead-studs and flexible-plate connectors located under the retaining ring. At each
end, one stud is provided for each polarity. The stud is made of flexible-plate
connections compensate all mechanical and thermal stresses.
Retaining Ring
Retaining rings which carry the centrifugal forces of the rotor end windings are
fitted at each end of the active part of the rotor.
Each retaining ring has a cylindrical section and disc-shaped cap end.
The retaining rings are shrunk onto the rotor ends and maintained in their axial
position by means of a bayonet attachments. A special key prevent any
movements of the rings in the tangential direction under short circuit conditions.
A special feature is the insensibility of the used steels against stress corrosion.
Cooling System
The axial fans at both ends of the motor provide for two cooling circuits. The air
which cools the rotor enters the end-coil space between the end bells and the
shaft. In the vicinity of the slots it flows through slits into the hollow conductors,
where the air flow is being divided. One flow path is through the hollow
conductors in the slots, entering the air-gap at the middle of the rotor through
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radial passages in the windings and slot wedges. The other one leads through
the hollow conductors in the end-coils, finally leaving the space under the end-
bells through slots n the rotor body and entering the air-gap.
Some of the air which cools the stator is led straight into the air-gap. Together
with the cooling air from the rotor end-coils, it leaves this region through radial
passages in the frame. From there the air returns via the coolers to the fans. The
rest of the air cools the stator end-coils and flows through axial channels into the
second frame chamber. From there it flows through the laminations towards the
air-gap where it splits up again. One half flows back through further slots into the
first frame chamber, the other half mixes with the air coming from the rotor at the
middle of the machine. From there the air passes through the laminations to the
third frame chamber, the coolers and aging to the fans.
Each of the cooling elements consists of a finned tube bundle and two water
chambers. The materials for the coolers will be selected depending on the quality
of the water. The coolers can be cleaned easily with brushes.
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Bearings
The generator is equipped with two journal bearings. The bearing at the driven
end is part of the immediate block of the gas turbine. The bearing on the non-
driven end is insulated to prevent shaft currents. The rotor is earthed via earthing
brushes. The bearings are connected to the lub and jack in oil systems of the
turbine.
Slipring Unit
The equipment for conducting the excitation current (direct current) into the
rotating rotor in order to produce the magnetic field in the rotor winding is located
in the slipring unit at the non-driven end of the generator. It consists mainly of two
slip rings shrunk onto the shaft (but insulated from it), a set of carbon brushes in
contact with the slip rings and carried in replaceable holders, and the brush-
holder supports. The actual transfer of current takes place between the brush
surfaces and the slipring surfaces. The constant pressure required between the
surfaces is provided by rolled-strip springs on the brushes.
The heat generated in the slip rings and brush gear is removed by a dual exhaust
fan which draws cooling air through each side of the unit. During operation, the
brush gear can be inspected through safety-glass windows provided in the
casing.
Temperature Monitoring
Temperature sensors are provided in the stator winding and the cooling air
circuit. The connecting wires to the sensors are brought out through bushings to
the instruments terminal box.
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10. Excitation System
General Description
The synchronous generator is shunt excited. The power required for the
excitation is taken from the generator terminals and fed to the field winding
through the excitation transformer and the thyristor-controlled rectifier units. The
thyristor-controlled by the voltage regulator through the grid control unit and
pulse amplifier stages, so that the generator voltage is held almost constant from
no load to rated load. A fully-controlled 3ph AC bridge circuit is used for the
rectifier circuitry. This permits reversing of the polarity of the excitation voltage
during rectifier operations ensuring rapid control during build-up or discharge of
the field.
A three phase AC auxiliary gird is required for field flashing for the generator
excitation which is supplied via the transformer and the field flashing circuit
breaker until the generator is excited to such an extent that the excitation
equipment can operate automatically. When a fault occurs, the generator can be
deenergized quickly with the field circuit breaker and the voltage dependent
resistor. The short circuit device protects the excitation equipment and the
thyristors from excess voltage by short circuit the field windings through the
limiting resistor.
Description of Operation
Regulator rack
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The actual value and set point are compared in the Unitrol Section and the
difference between the two is amplified in the control amplifier. The output
voltage of the amplifier is limited to a value set by an internal potentiometer. The
generator is controlled as follows below the cut-off frequency F. the control
voltage is proportional to the frequency, and above this the voltage is held
constant to a set value (see fig. 23)
Figure-23
The cut-off frequency can be adjusted by an internal potentiometer. The set point
adjustment is made using a reference value transmitter Unitrol, which is installed
in the regulatory rack.
Adjusting elements allow the level and range of the voltage regulator to be
selected (see fig. 24)
Figure 24
PMI,NTPC 93
Adjustable compound resistances are connected in the circuit to ensure the
required reactive load distribution during parallel operation with other generators.
The resistors allow the regulator drop to be changed. AP. I.D. feedback filter and
a differential amplifier are used for stabilizing, which permits optimum matching
of the controlled generator. A power pack supplies a stabilized voltage to the set
point potentiometers.
Grid control unit automatic channel and manual channel the output signal of the
regulator rack or manual control potentiometer is fed to the input of the grid
control unit Unitrol together with a 3ph A.C. voltage from the filter Unitrol which is
synchronous with and has the same phase as the supply for the power rectifier.
From this, 6 phase voltages are formed, which are compared with the regulator
or hand control signal (see Fig. 25). The differences is formed into square wave
form voltages by an operational amplifier with controlled limits. Six trigger pulses
are thus formed at 60 (electrical) intervals by the change in polarity.
Figure-25
The trigger pulses can be shifted depending on the size of the AC and DC
voltage. For safety reasons, adjustable limits are provided for full rectifier or DC-
AC converter operation. The weak pulses of the grid control units 1001c-P are
PMI,NTPC 94
amplified in the pulse stages of Unitrol. Control relays in the unit allow the pulses
to be suppressed, i.e. blocked, or to be reversed in DC-AC converter operation.
The output pulse of the grid control unit are fed to the parallel-connected pulse
end stages of Unitrol. These end stages are designed to control up to a
maximum of 8 thyristors in parallel per branch by means of the appropriate pulse
gradient and power level, i.e. a 3ph AC bridge with up to 48 thyristors can be
controlled. The pulse of every end stage can be suppressed by means of a
blocking relay. The corresponding thyristors therefore remain isolated.
Current rectifiers
Three current rectifiers unit are fitted in section of the lead rectifier cabinet. The
thyristors are directly fitted to the heat sinks. The current strips are connected to
the DC AC busbars, the auxiliary and control cables are lead to the appropriate
terminal blocks. Each unit is ventilated by its own fan. The fans are supplied
through the fuses, which are directly connected to the secondary voltage of the
excitation transformer, the transformer, and the protection circuit breaker. The air
flow from the fans is monitored by a wind vane relay.
Limit criteria
All limits act equally in that they influence the voltage control and alter the
excitation accordingly.
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Too large a stator current
In the over-excited range, the rotor or stator current limiter reduces the excitation
and in the under-excited range the load angle limiter increases the excitation.
The rotor or stator current limiter acts through a time delay and integrator to
maintain both good regulation in the event of load changes, and also the dynamic
behavior of the generator when intermittent grid faults occur. This allows the
protective system to operate selectively.
The load angle, the angle between the generator longitudinal axis the grid
voltage vector, can be determined by forming a vector diagram of the generator
and the external reactance. The generator voltage and current are fed to the
input of the load angle control limiter. The quardrature reactance xq of the
generator is the determining parameter, and can be adjusted between 0.5 and
3.0 p.u. While the external; reactance xe can be adjusted between 0 and 3.0 p.u.
by means of potentiometer: The two voltages so formed enclose an angle
between them which corresponds to the load angle. This angle is transformed in
a transducer to a DC voltage signal. This angle is transformed in a transducer to
a DC voltage signal. This signal is compared to an adjustable set point. When the
measure value exceeds the set point, the limiter comes into operation and acts
upon the voltage regulator. The excitation is then increased until the load angle
corresponds to the adjusted set point. Despite increasing generator voltage, the
voltage regulator remains ineffective.
PMI,NTPC 96
Rotor current limiter Unitrol
This limiter protects the rotor winding from thermal overload. The excitation
current is measure on the AC side at the supply to the controlled rectifier units,
and converted into a current proportional DC voltage within the limiter. This is
then compared with an adjustable set point, amplified and fed to the input of the
voltage regulator. The limiter acts with a time delay, so that the dynamic control
is not affected in cases of fault.
PMI,NTPC 97
Basically the system consists of two units :
The supply for power rectifier is from the 3ph excitation transformer which
receives its power from the generator. Before excitation takes place at rated
speed, there is only the residual voltage of the generator available. This is
insufficient for starting the excitation equipment. The thyristors of the controller
remain blocked. An auxiliary voltage of 414 V, 50 Hz is available for field flashing,
which supplies sufficient excitation current through the matching transformer and
diode bridge for 35% of the generator voltage. The on command is given by the
start-up automatic, or from the control room, via the decontic control. The
command is only given when the criterion ready for connection is fulfilled. The
field breaker is switched on.
At 70% generator voltage the voltage relay switches the field flashing breaker off.
Switching off must take place within 20s, otherwise the time supervision switches
the field breaker off. The excitation process will be interrupted.
De-excitation
PMI,NTPC 98
(a) By the command Excitation off via the contactor from the automation or
from the control room.
(b) By a fault within the excitation equipment.
(c) By the generator protection.
The field breaker is immediately opened and the field discharges through the
voltage dependent resistor. The excitation circuit must not be broken as long as
current is flowing, since this can cause high voltages which would damage the
thyristors or the rotor winding. When the filed breaker is switched off, a contact
switches the resistors in, parallel with the rotor winding. A second contact breaks
the supply from the rectifier. The resistor is sized so that the over voltage of the
filed breaker. The resistor is designed as nonlinear and voltage-dependent,
whose resistance decreases with increasing voltages. In this way the de-
energizing time constant becomes shorter. The blocking voltage of the thyristors
lines above this cut-off overvoltage.
The overvoltage short-circuit device, parallel to the rotor winding, offers additional
protection as undesired break in the rotor circuit occur during operation. When
the short circuit device acts, the limiting resistor is switched in parallel to the rotor
winding. It acts between the allowable switching voltage of the field breaker and
the cut-off overvoltage, so that it is only activated when a fault occurs.
Power supply
Automatic voltage regulator and manual voltage control have two independent
power supply units each, one AC-DC converter and one DC-AC converter. The
AC-DC converters Unitrol are connected to the secondary side of the excitation
transformer via transformer. The DC-AC converters Unitrol are fed from the 220
PMI,NTPC 99
V DC distribution AC-DC converter Unitrol connected to the 220 DC distribution
serves for power supply for the protection.
Control Voltage
The control voltage is monitored by, which gives a signal the voltage is low.
Every function has its own control circuit, so that when failure occurs, only a part
of the system is out of operation. When a failure occurs in the circuit it must be
decided whether the excitation equipment can remain in operation or not,
according to the importance of the faulty circuit. The faulty control circuit must be
brought back into operation again as soon as possible. The protection switches
are monitored by the built-in auxiliary contacts. When a protection switch cut out,
the alarm Protection switches Voltage is illuminated in the control cabinet and in
the electrical control room the excitation warning signal is given. Normally only a
small amount of power is taken from the battery for the controls. Switching
process require approx. 10 KW for a short period.
When the generator is stationary the circuit diagram shows that field breaker is
open. The generator must be brought up to rated speed before it can be put into
operation. Above 95% rated speed, the excitation process can be started by
switching on the field breaker. The generator is excited up to 35% rated voltage
by the filed flashing. Above this value the electronics function reliably, and the
regulator takes over the control of the generator voltage. At 70% generator
voltage the field flashing is switches off by the field flashing breaker. The set
point is compared to the actual value. During the excitation process the generator
PMI,NTPC 100
voltage is low. The control amplifier Unitrol 2010 gives a higher signal to the grid
control unit Unitrol.
When manual control has been selected, then the firing angle of the thyristors
can be adjusted with the hand potentiometer, which corresponds to a certain
exciter voltage. The actual value of the generator voltage has no influence on the
firing angle-in contrast to the automatic control-since with manual control, there is
no closed control circuit. When the potentiometer is changed as a result.
The changeover to manual channel can be made at any time. However the pulse
difference between the output of the grid control unit automatic channel and the
grid control unit manual channel must be zero. The pulse difference can be read
off on the comparative voltmeter via the measurement Unitrol 0040, comparator
Unitrol and measuring converter. The comparison is made in the control room via
the contractor by adjusting the potentiometer. When zero voltages is shown on
the comparative voltmeter, a smooth changeover can be made to manual control.
PMI,NTPC 101
Alarms
The signals for the excitation equipment are shown on the circuit diagrams. They
are illuminated in bottom for acknowledgment, lamp test, functional test and lamp
reset.
Electronic inverse time overcurrent relay type IKC 062 delay trip (change-over to
manual), instantaneous trip.
PMI,NTPC 102
11. Gas Plant Operation
Start up or shut down of G/T, WHRB and S/T of each module is performed
separately from the other module (except for S/T gland steam back-up
and heating steam back up systems).
Start up/shut down mode is selected freely form among those mentioned.
The start up/shut down procedure for WHRB and S/T here mainly describes
operating procedure for G/T by-pass damper, WHRB inlet damper and remote
operated valve necessary for start up and shut down from G/T exhaust gas
admission to WHR till rated load operation of S/T. For detail operating procedure
for G/T WHRB, S/T auxiliaries and remote operated valve following procedures
are followed.
Start up Mode
The start up mode of G/T, S/T and WHRB shall be selected from among the
following as a rule through various other start up modes are conceivable
according to power demand and operating principle.
This mode is two unit (2G/Ts + 2WHRBs +1 S/T) combined cycle start up
mode which, after starting up one each of G/T and WHRB, starts up the
PMI,NTPC 103
other G/T and WHRB and brings the output of G/T and S/T the target
output of the module. In this mode, S/T is loaded with one each of G/T and
WHRB in operation, and after the intial load is achieved, the pressure
control of HP/LP by-pass valves of both WHRBS is changed to common
pressure control and then S/T is loaded up.
The timing of starting up the other G/T and WHRB is left to the discretion
of the operator, and S/T is kept stand by at the initial load until the
pressure control of both WHRBS is changed to the common pressure
control.
This is a mode of starting up both G/Ts and WHRBS at the same time,
changing the pressure control of HP/LP by-pass valves of both WHRBS
to the common pressure control, then loading up and brining G/T the
output of and S/T to the target output of the module is achieved.
This mode is used only for start up after right stop or hot start up (with
vacuum).
In other start up modes; in which the time from G/T start up to S/T loading
is long, simultaneous startup is not made to reduce heat lose at start up.
This is a mode of starting up the other G/T and WHRB one until combined
cycle of G/T, WHRB and S/T is in operation. In this mode, the HP Steam
pressure and temperature of the other G/T and WHRB are raised up those
of G/T and WHRB in operation, and then the pressure control of HP/LP
PMI,NTPC 104
by-pass valves is changed to the common pressure control, and S/T is
loaded up.
This is a combined cycle start up mode of starting up S/T with only one
each of G/T and WHRB in operation. The other G/T and WHRB remain
stopped.
Loading of S/T
S/T loading rate after HP/LP by-pass are fully closed and HP/LPCV are
fully opened is determined by the load change rate of G/T, namely S/T
load change rate increases as G/T load change rate increase. (Except for
G/T/WHRB additionally start up mode).
S/T unloading rate too is determined by G/T load change rate under
HP/LP by-pass valves are fully closed and HP/LPCV are fully opened.
STARTUP PROCEDURE
Cold start up
PMI,NTPC 105
The condition in which HP turbine rotor temperature is below 120 degC is
called cold condition.
In cold start up, the HP turbine rotor needs warming, which is performed to
raise the rotor temperature above the transition temperature of the rotor
material 120deg.C and prevent brittle fracture in high speed operation to
achieve this heat sock is done by holding rotor speed at 2000 rpm during
start up of the steam turbine. The time of heat soak varies with rotor
temperature before steam admission. Heat soak time of 2 hours is given
on the assumption that the rotor is at the ambient temperature.
Heat soak is performed with one G/T in operation to reduce start up loss
and the other G/T shall be stared up just before that soak is completed.
At cold start up, WHRB outlet steam temperature must be below 430 C
because of temperature limitation at steam admission to S/T. Therefore,
WHRB inlet exhaust gas temperature must also be limited accordingly.
WHRB and S/T shall be started up after G/T load is held at a load (about
30%) at which boiler outlet steam temperature can be kept below 4300 C.
Start up conditions
PMI,NTPC 106
Rise (0-29 kg/cm2) (at G/T 30% load)
WHRB temperature rise rate 4002 C/h
S/T speed rate 300 rpm/min
S/T load up rate
(Before HP by-pass valve full close) 1%/min.
(After HP by-pass valve full close) 2.5%/min.
Start up procedure
WHRB start up
PMI,NTPC 107
- Start up boiler circulating pump
- Make sure that by-pass damper is full open and WHRB inlet
damper is full shut.
- Start up G/T after all preparation for G/T start up have been
complete.
- Open HP/LP drum air vent valves and SH outlet air vent valves.
- Until HP/LP by-pass valves are put into operation, open SH outlet
blow valve, HP steam pipe drain valve and LP steam pipe blow
valve, and steam is blown into the WHRB blow down tank and S/V
flush pipe.
PMI,NTPC 108
- Opening HP steam pipe drain valve is automatically adjusted
according to HP steam temperature at start up of WHRB.
- When HP/LP by-pass valves are put in operation, fully close by-
pass damper.
PMI,NTPC 109
S/T start up
- Make sure that all preparations for S/T start up have been
completed
- Startup the other G/T just before heat sock is completed and hold it
at 30% load, increase steam temperature and pressure of the other
WHRB and when HP/LP steam pressure reached 27/cm2 and
4.5/cm2 respectively, put HP/LP by-pass valves in operation.
(To start up the other G/T and WHRB, follow the startup procedure
described earlier).
- Loading.
PMI,NTPC 110
Load up
- When S/T load reaches 20% full close all turbine drain valves.
- Fully close HP main steam stop valves for other WHRB adjusting
temperature and pressure differences.
- Fully close LP main steam stop valve for other WHRB, adjusting
temperature and pressure differences, fully close LP turbine by-
pass valve according to the predetermined programme and then
switch to back-up control
- When HPLP by-pass valves are fully closed, adjust G/T output to
achieve target plant output.
- At this time, adjust G/T load up rate so that the S/T load up rate will
be 2.5% min. (GT load up rate will be approx. 2.9% min.)
Warm Startup
PMI,NTPC 111
Because of thermal stress, heat soak from 0 to 40 minutes is required,
depending on the steam turbine rotor temperature. Startup procedure is
basically the same as is cold start up. When making a weekend shut down
of the plant, if a normal shutdown is made, the steam turbine rotor can be
held at a relatively high temperature, and so heat sock time can be
shortened.
If, rotor metal temperature is above 300 C, and heat sock is not required.
Start up conditions
PMI,NTPC 112
Star up Procedure
WHRB start up
PMI,NTPC 113
Start drain blow Opening HP steam pipe drain valve and LP steam
pipe blow valve.
Valve and steam is blown into the WHRB blow tank down tank and
S/T flush pipe.
- When HP/LP by-pass valves are put in operation, full open WHRB
inlet damper and full close by-pass damper.
PMI,NTPC 114
- After HP/LP by-pass valves have been put in operation, shut SH
outlet blow valve, HP steam pipe drain valve and LP steam pipe
blow valve.
S/T Start up
Make sure that all preparations for S/T start up have been
completed.
PMI,NTPC 115
Start accelerating. Accelerate at 300 rpm/min. upto target speed of
3000 rpm. Make rub checks as necessary during acceleration.
Loading.
After initial load operation is over, open HP/LP steam stop valve of
the other WHRB, and change pressure of the other WHRB and
when HP/LP by-pass valves in operation.
Loading.
After initial load operation is over, open HP/LP steam stop valve of
the other WHRB, and change pressure control of HP/LP by pass
valves to common pressure control.
Load up
When S/T load reaches 20% full close all turbine drain valves.
PMI,NTPC 116
When LP by pass valves is fully closed, shift LP by-pass valve to
back up mode.
Startup conditions
PMI,NTPC 117
Steam evaporation at G/T 50% load 25t/h
Start up procedure
PMI,NTPC 118
- Start up chemical injection system.
- Make sure that all preparations for start up have been completed.
WHRB startup
- Make sure the by-pass damper is full open and WHRB inlet damper
is full shut.
- Start up G/T After all preparations for G/T start up have been
completed.
- After G/T is loaded, open WHRB inlet damper upto 100% opening.
- At boiler start up fully open LP main steam stop valve and HP/LP
by-pass stop valves in operation automatically by individual
pressure control.
PMI,NTPC 119
- At that time, opening of SH outlet blow valve and LP steam blow
valve is automatically adjusted according to HP steam pressure at
start up of WHRB.
- When HP/LP by-pass valves are put in operation, fully close by-
pass damper.
S/T start up
- Make sure that all preparations for S/T start up have been
completed.
- Loading.
PMI,NTPC 120
- Maintain 15% initial load.
Load up
When HP/LP by-pass valves are fully closed, adjust G/T output to
achieve target plant output.
While the plant is in partial load operation, the number of G/Ts in operation is
changed in some cases to increase efficiency of plant operation. When
starting up G/T and WHRB in such case, the start up procedure must be such
that minimize the temperature difference between high pressure steam of the
plant in operation and high pressure steam in G/T and WHRB to be started
up.
PMI,NTPC 121
Start up conditions
Startup procedure
WHRB startup
- Make sure that by-pass damper is full open and WHRB inlet
damper is full shut.
- Startup G/T after all preparations for G/T startup has been
completed.
- Open HP/LP drum air vent valves and SH outlet air vent valve.
PMI,NTPC 122
- When HP steam pressure reaches 2kg/cm2g, automatically close
HP/LP drum air vent valves, and SH outlet air vent valve.
- When LP/HP by-pass valves are put in operation, fully close by-
pass damper.
PMI,NTPC 123
Load up
When HP/LP by-pass valves are fully closed, adjust G/T output
to achieve target plant output.
PMI,NTPC 124
- Bring down S/T load to 15% by opening the HP/LP by pass valve of
both WHRBs
- When ST speed is less than 400 RPM. Close WHRB inlet damper
of both WHRBs.
PMI,NTPC 125
UNIT I UNIT-II
CONDENSER VACUUM
BREAK COND. VACCUUM
<-100 mm of hg
Gland steam Group off
PMI,NTPC 126
WHRB out off shut down
In this shut down only WHRB is taken out of service. ST will be in service
with second WHRB. Corresponding GT may be stopped as per the
situations.
PMI,NTPC 127
CONFIRM HP CV CONFIRM LP CV
SET 29 KG/CM2 SET IN 5 KG/CM2
GT SHUTDOWN IF REQUIRED
PMI,NTPC 128
MALFUNCTION AND REMEDIES
3. Too high temp. of a. Too much of exhaust 1. Investigate the gas turbine
flue gas gas
flow
PMI,NTPC 129
SHUT DOWN PRODECURE
- When all load been removed, shut-down the unit by tripping either
manually or remotely.
This closes all the turbine HP steam and LP steam valves and
disconnects the generator from the line.
- Make sure that the auxiliary oil pumps starts when the bearing oil pressure
drops below 0.85+0.05 kg/cm2.
- In order that the turning gear will be remotely engaged, be sure that the
rotor speed is below the turning speed before the control switch is turned
to the START position. This will also supply oil to the turning gear.
- Shut-down the auxiliary oil pump and make sure that the turning gear oil
pump starts when the bearing oil pressure drops below 0.75+0.05 kg/cm2.
- Open the vacuum breaker when the turbine speed reaches about 400
rpm. Shut down the air removal equipment.
- When the vacuum has reached zero shut-off sealing steam from the HP
steam header to the gland steam control value and shut down the gland
steam condenser exhauster.
PMI,NTPC 130
- Regulate water to the oil cooler to maintain the temp. of the oil leaving
the coolers between 350 C and 380 C, if possible.
- Since the governor is in such a position that the no load speed is higher
than 3,000 rpm, the speed will rise will suddenly at a rate proportional to
the electrical load lost.
- This sudden speed rise will cause the acceleration response feature of the
governor momentarily to assume control of the turbine, and close the both
HP and LP control valves rapidly.
- With the both LP and HP control valves closed, the speed of the unit will
decrease at a rate depending on the residual load left on the gtenerator.
PMI,NTPC 131
Loss of Pressure or Temperature
If the initial pressure regulating system is cut out or inoperative the following
procedure will apply:
- Place unit on turning gear, note power input to turning gear motor and
listen for rubs. If everything is normal, follow standard starting procedure
to bring unit up to speed and synchronize.
- For the case where the pressure can be held above 80% of normal and
temperature to less than 830C drop, bring the unit up in normal manner
after temperature and pressure have been restored to normal.
- If the unit trips from a known cause resulting from testing, etc. or if the
vacuum is lost, let the unit come to rest and place on turning gear.
- Check the rotor for truth. If everything is normal follow Normal Starting
Procedure.
- Where vacuum and speed can be held, reset overspeed trips and proceed
with synchronizing the unit.
- For the case where vacuum is lost and the low vacuum trip mechanism
trips the load and unit, let the unit come to rest and place on turning gear.
PMI,NTPC 132
- Clear vacuum trouble and follow Normal Starting Procedure.
- This unit is equipped with protective devices, which trip the unit in the
event of low vacuum. Low bearing oil pressure and axial shift.
- In addition, the unit can be tripped, either with the trip solenoid or with
hand trip lever.
- The situation can also arise where by the unit is inadvertently tripped in
the process of testing the protective devices if the overspeed trip test lever
is released prematurely.
- In the event the unit is tripped as noted in above and the trouble has been
recognized, cleared and the vacuum maintained, relatch the unit and
proceed to synchronize.
- If in the even of a trip and the vacuum is lost let the unit come to rest,
following the normal shut-down sequence. After the trouble is corrected,
restart the unit in accordance with the normal starting sequence.
ST OIL GROUP
GROUP GROUP ON
ST TURNING GROUP
GROUP GROUP ON
ST DRAIN GROUP
GROUP GROUP ON
CONDENSATE PRE HEATER IN AUTO HP 2nd
PMI,NTPC 133
Economizer and LP economiser Recirculation valve
on auto.
1st GT 2nd GT
GT Load Down from UCD or UCP DT Load Down form UCD or UCP
If GT Load = 50% If GT Load = 50%
Take HP TB PC coned. Take HP TB PC coned
INDIVID INDIVID
Take HT TB PC coned. Take HP TB PC coned
INDIVID INDIVID
PMI,NTPC 134
OPEN GT BYP ASS DAMPER OPEN GY BYP ASS DAMPER
HP and LP drum level will go
down. Increase SV to + 50mm as
after 10 min closing the inlet
damper the drum Level will min.
and go further down.
PMI,NTPC 135
- Keep only one see each of the following auxiliaries, and stop if more than
one running.
PMI,NTPC 136
LP main steam pressure high > 7 kg/cm2
LP Main steam Temperature High > 1750 C
LP main steam Temperature low < 1500 C
LP exhaust Temperature High > 800 C
HP Differential expansion
Low Low -2.30mm
Low -1.70mm
High +4.70mm
High High +5.70mm
PMI,NTPC 137
- Lubricating Oil temperature High 500C
- HP Oil pressure low 16kg/cm2
- Main oil tank level low FL +2165mm
ST Run Back
Run Back on ST will operate automatically if ST load > 50% and its load will
come down to 45% in the following cases.
i) Out of the 2 running CEP one trips and 3rd one does not starts on auto.
ii) Out of the 2 running HP BFP one trips and 3rd one does not starts on
Auto.
iii) Out of the 2 running LP BFP one trips and 3d one does not starts on Auto.
PMI,NTPC 138
Soaking Time in Warm Start (in minutes (M.T.)
S= 5 + 8T = 9M} {P {3 x 2 + 14}
50 200
For conservative time estimation last term can be neglected which is negative
(and negligible)
S = 5 + 8T = 9 M Minuets
50
Curtain spray
Certain spray will start when CEP is running and any of HP & LP. TB By pass
valve i/v and control valve open.
System Alarm/Trips
The following alarm./trips are provided to safe guard the operation of steam
turbine.
PMI,NTPC 139
Main oil tank level high FL + 2565 mm
Main oil tank level low FL + 2165 mm
Thrust bearing wear alarm 2.10+0.2kg/cm2
Thrust bearing wear trip 5.3-5.6kg/cm
Bearing oil pressure low alarm 0.75+0.05 (bearing oil) kg/cm2
Bearing oil pressure low trip 0.52 kg/cm2
Turning oil pump auto start 0.75+0.05 (bearing oil) kg/cm2
Emergency oil pump auto start 0.65+kg/cm2
HP oil pressure low alarm 18.0 kg/cm2
Aux. oil pump auto start 0.85+0.05 (bearing oil) kg/cm2
Oil cooler outlet oil temp. high 500C at 900 rpm to rated
400C turning to 900 rpm
Axial shift alarm at 2.1+0.2kg/cm2 (trip control oil)
Turbine trip indication 3.0+0.2kg/cm2 (auto control oil)
Turbine reset indication 6.0+0.2 (auto stop oil)
Turbine trip test indication on 3.0+0.2kg/cm2 (at trip test)
Turing gear interlock 0.3kg/cm2 (bearing oil)
Journal bearing metal temp alarm 107o C
journal bearing metal trip 113oC
thrust bearing metal alarm 99oC
thrust bearing metal trip 107oC
bearing oil drain tem alarm 77oC
Main oil transfer pump takes suction from bottom of main oil tank and transfers
the oil to the dirty oil storage tank. From dirty oil storage tank the dirty oil is fed to
plant oil purifier and after purification oil is stored in clean oil storage tank. From
clean oil storage tank the oil is transferred back to main oil tank by clean oil
transfer pump.
Main oil transfer pump, plant oil purifier, dirty oil storage tank clean oil storage
tank and clean oil transfer pump are common for both modules.
PMI,NTPC 140
Turbine Gear Operation During Shut-Down
In order to facilitate starting, the turning gear should be in operation and should
preferably have been in operation through-out the shut-down period
Even after the turbine is comparatively cool, this offers minimum time lost in
starting and an assurance of safety in the even of any leakage of steam in to the
turbine during the shut-down period.
When it can be arranged without delaying work schedules, the turning gear and
the oil circulation system should be kept in operation for not less then 48hours
after shut-down.
In the event that continuous rolling during shut-down is not practical, the turning
gear should be started again at least an hour before rolling the turbine with
steam. It should remain in operation sufficient length of time be fore admitting
steam to the turbine to allow the rotor to become straight with in the limits noted
in the section on Limit son operation.
Recognizing that tha preceding schedule may not be practical in case repairs or
adjustments are to be made to the turbine, the following schedules are
recommended as the absolute minimum periods considered satisfactory under
various circumstances.
PMI,NTPC 141
If an emergency necessities it, the turning gear may be shut down
immediately. However, it must be recognized that this may subject the
rotor to a severe bow. It must not be used for continuous rolling unless
the bearing lubrication system is operating.
Bearing oil circulation must be maintained after shut down to protect the
bearing against overheating.
Both the turning and bearing oil circulation systems are to be kept in
operation for a minimum of 12 hours; oil temperature from the cooler
should be maintained below 35oC. if possible.
Both the turning gear and the oil circulation may then be shutdown. If
operation of the unit is to be resumed before the turbine is thoroughly
cooled, the turning gear should be started 3-4 hours before rolling the
unit with steam.
Depending upon the nature of the work to be done, the following shedule
may be adopted.
Keep the turning gear and the oil circulation systems in operation for a
minimum of 3 hours. Both systems may then be shut off for a period of
PMI,NTPC 142
not more than 15 minutes; if practical, however, oil circulations should be
maintained.
Following the 30 minute shut down period as above, the turbine should
again be rolled on turning gear with oil circulation for a minimum of 2
hours.
In any case, if the turning gear has been disengaged, it should be put in
operation a sufficient time before admitting steam to the unit to allow the
rotor to become straight within a limit of approximately 0.025mm on the
truth indicators or within a limit of approximately 0.05mm on the
eccentricity recorder indications.
System Alarms
The following alarms and shutdown point are provided for gas turbine protection.
PMI,NTPC 143
- Lube oil Temperature High - Alarm
- Lube oil tank level Abnormal - Alarm/shutdown
- Inlet Air Filter Abnormal - Alarm
- Vibration high - Alarm
- Vibration high - Alarm/shutdown
- Exhaust gas temperature - Alarm/Shutdown
- Gas Pressure Supply Pressure Low - Alarm/Shutdown
- Liquid fuel Main Pump Trip - Alarm/Shut down
- Gas Leakage - Alarm
- Liquid Fuel Drain Tank Level Hi - Alarm
- Over speed - Alarm/Shut down
- Exhaust Gas Pressure Hi - Alarm
- Exhaust Gas Pressure Hi - Alarm/Shut down
- Flame Out - Alarm/Shut down
- Flame Detector Abnormal - Alarm
- Blade Path Temperature Spread Hi - Alarm
- Disc Cavity Temperature Hi - Alarm
- Turning Gear Trouble - Alarm
- Bleed Value Abnormal - Alarm/Shut down
- Acceleration Rates Insufficient - Alarm/Shut down
- Auxiliary Motor Abnormal - Alarm
- SW Position Wrong - Alarm
- Inst. Air Pressure Low - Alarm
- Electrical Fault - Alarm/Shut down
Emergency Operation
The Gas Turbine System can be operated in an emergency during the following
conditions:
PMI,NTPC 144
- Immediately tighten nuts, bolts or fasteners, if leak cannot be stopped the
gas turbine must be shut down and repairs made.
- If a fuel leak occurs prompt action must to taken to contain and repair the
leak. If the leak cannot be controlled the gas turbine must be shut down.
- Many factors affect vibration, the cause of any abnormal vibration must be
found and corrected. Unsteady blade path temperature, high bearing
temperatures, turbine rotor rubbing against the turbine casing, speed and
load will all directly or indirectly affect the amount of vibration.
- Alarm and trip devices will shut down the unit if vibration exceed 0.200
mm (Peak to Peak).
- If the gas turbine speed exceed its specified low frequency operating
range, compressor surging can occur. If surging occurs the unit must be
shut down immediately and inspected for damage.
PMI,NTPC 145
Turbine blade resonance is produced by blade conditions above or below the
blades normal operating frequency range. Turbine blade resonance is a main
concern of low frequency operation. When operating below Hz the unit must be
monitored for abnormal noise and vibration. If unit frequency falls below 47.5 Hz
for more than 15 seconds or falls below 47.0 Hz it will automatically trip.
Dependable, economic operation over long periods of time is only possible if the
equipment is maintained and operated according to the manufacturers
instructions. If problems develop, they should be traced and corrected as soon as
possible.
Potential Problem - Gas turbine starting motor will not start when
GTSTART push button is depressed.
Possible Causes - Unit auxiliaries not running, starting motor circuit not
operating Properly.
Potential Problem - Gas turbine trips at ignition and light off sequence.
PMI,NTPC 146
out of adjustment (liquid fuel firing only), blade path
temperatures during light off abnormal.
Abnormal Operation
- Low-frequency operation
- Maintaining low auxiliary load on the unit
- Steam turbine motoring
Limits for operating frequency and time at frequency are given for the protection
of the turbine and generator during under-frequency over-frequency operation.
For the turbine prevention of resonant operation of the tuned blades is the major
consideration. Operating limits have been developed form engineering analysis
coupled with laboratory testing and extensive field telemetry testing.
PMI,NTPC 147
Time limits are based on fatigue life consideration and have been apportioned to
the more prevalent under-frequency operating mode. For specific blading styles,
more conservative off-frequency operation limits have been imposed than
previously published. Generator operating limitations are also presented which
must be observed during off-frequency situations in order to prevent undesirable
thermal excursions of generator components.
In the design and design verification process, great care is taken to properly tune
the tapered and twisted blades that constitute the last several stages in the L.P.
turbine element.
Most turbine generator units are designed to withstand complete isolation from
the system and remain in service at no load or at an auxiliary load level.
However, it should be recognized that some of the larger plants now in operation,
and under construction, have plant control interlocks which automatically trip the
complete plant in the event of load separation.
PMI,NTPC 148
The transient stress in the turbine rotor is a factor to be considered when
suddenly dropping from full power out to auxiliary load and the subsequent
rapid application of load after the connection to the system is reestablished.
Motoring occurs when the steam supply to the turbine is shout while the
generator is still On the line.
PMI,NTPC 149
- Closing all governor valves during shut- down operation.
- A turbine- generator unit should not be motored for any extended period
without ventilating steam being admitted to all turbine elements.
Interlock for turbine motoring is installed to protect turbines from the damaging
effects caused by motoring and lack of ventilating system.
PMI,NTPC 150
Emergency Operations
Main Control Broad is connected to the grid with two 200 KV lines terminating
220KV and two 400 KV lines terminating at 400 KV. At Main Control Broad
the interconnection between 220 KV and 400 KV Buses is through two ICTs
each of 325 MVA capacity.
Black out condition may occur when all the four lines trip or there is failure of
supply at both 220 KVS/S and 400 KV S/S. In case both 220 KV lines trip
and 220 KV side breakers of ICTs also get opened then a circuit called
House Load Circuit gets triggered. This will cause tripping of both STs and
desynchronization of all the GTs except one reselected GT which will supply
House Load of Gas Plant. In all other conditions units at Gas Plant will trip on
high frequency or low frequency (Grid sinking).
In case of total power supply failure Gas Plant provision has been made of
Emergency Gas Turbine (EGT) to run essential auxiliaries and to start one
Gas Turbine. One Emergency D.G.Set has also been provided to keep the
units on turning gear in case of non-availability of EGT.
Following operation shall be carried out in the condition of black out (i.c.,when all
the efforts to save one of the GTs for House Load have failed ):-
- Ensure that DC Lub. Oil pumps and DC Seal Oil Pumps have started in
auto, if not start manually.
PMI,NTPC 151
- Charge Station 6.6 KV SW/GR (one bus only) from EGT and charge
auxiliary transformers one by one. Put on sufficient lights
- Start cooling Water Circulating Pumps (110 KW) for GTs and then one
IAC.
- Ensure starting of AC Lub. Oil pumps of GTs and TG Oil Pumps of STs.
Then stop DCLub. Oil Pumps. Start AC Seal Oil Pumps of all the units and
then stop DC Seal Oil Pumps.
- In case EGT is not available then Emergency D.G. Set shall be started.
Other restorations are to be done only after power Supply is made
available from the grid. IOCC and 220 KV S/S shall be contacted for
restoration of grid supply, so that start up power can be made available to
the Gas Plant.
- Start6 on PAC.
- Start the selected Gas Turbine and keeping both 220 KV lines and ICTs
out of service charge one 220 KV Bus (In case Grid supply has not been
restored till that time).
- Take one Station Transformer into service (which can feed to the other
dead 6.6 KV Bus)and transfer station auxiliaries load to this transformer.
PMI,NTPC 152
Following shall be attempted only if Grid Supply has not been normalized.
- Start one more gas turbine and keep it ready for synchronization. This
units can also be brought on bar if the previously running gas turbine has
crossed a load of 20 MW. Then further load can be increased at the rate
of 10 MW/minute.
- After the grid condition are normalised EGS can be stopped. Get the other
220 KV line charged from the grid end and synchronize at Plant end.
Similarly synchronize the 400 KV lines, Bring the combined cycle into
service.
Normally when both the 220/400 KV ICTs are available, tripping of the 220KV
lines shall not pose much problem. However it shall be ensured that the other
220 KV lines and ICTs are not getting overloaded. To reduce the station load one
of the gas turbines can be desynchronized temporarily. If the overloading is
minor, then station load can be reduced slowly.
In case only one ICT is in service then changes of overloading 220 KV lines/ICT
are high and one or two gas turbines can be desynchronized temporarily,
depending on the amount of overload, to control the station the station load.
PMI,NTPC 153
Tripping of both 220 KV lines (Station Load Full)
Normally when both ICTs are available tripping of both 220 KV lines will overload
the ICTs slightly. The amount of overloading will depend on the reactive power
flow through ICTs. Depending on requirement, one of the gas turbines can be
desynchronized temporarily or the load on all the units can be reduced gradually
to a safe level. However , if only one ICTs is available at the time of tripping of
both the 220 KV lines, immediately two GTs shall be desynchronized, load on
remaining GTs shall be reduced and load on STs shall be reduced by operating
HP/LP bypass valves. If fast action is taken ICT will also trip on over load causing
House Load Circuit triggering. Another course of action can be, opening of 220
KV Bus coupler breaker. This action may however trip the units connected to the
bus, where 220 KV lines were connected earlier.
Same action as in above point no. 2 will have to be taken depending on the
loading of remaining ICT and 220 K V LINES.
Same action as above will have to be taken to avoid overloading of the 220 K V
lines.
PMI,NTPC 154
NO load ST Trip. Before this happens efforts can be made to bring down the
frequency by desynchronizing of the GTs manually and reducing be made load
on remaining GT. Simultaneously IOCC shall be contacted to control the
frequency. During this process HP/LP stop values of the out of service WHRB
shall be kept closed to a void tripping of ST on WHRB HP/LP Drum level High .
If the frequency comes down the GT shall be synchronized and WHRB shall be
taken into service immediately to avoid drop in outlet temperatures of WHRB.
If all the efforts fail the remaining GT will also get desynchronized and ST will trip
on GT No Load ST Trip. During this time efforts shall be made to keep the
WHRB s in steady operating condition by controlling the drums level and
operating the HP/LP bypass valves suitably. When frequency comes, GT s can
be synchronized and ST rolling can started to bring ST into service .
PMI,NTPC 155
12. Protection And Interlock
All electrical equipment must be protected against internal and external faults, as
well as abnormal conditions which may endanger the equipment or the system.
Appropriate relays and devices have to be provided, to detect the faults and
potentially dangerous conditions and to isolate the concerned equipment cost the
earliest in order to minimize the damage.
PMI,NTPC 156
It is also important that the control room operator is not burdened or confused
with too many alarms. The alarm facial on the unit control board (UCB) are
therefore to be used for annunciating only those abnormal conditions for which
the UCB operator has to take some distinct preventive or restorative action. It is
generally adequate and/or with hand reset flags on protective and auxiliary relays
panels or switchgear.
Protection of Generator & General Bus Against Bus Duct Against internal
Fault
The generator bring very costly and critical items in a power plant, should be
protected by duplicate protections. Phase to Phase Faults are to be covered by
differential relays 87G and 87GT. In case of CGB scheme 87 GT covers up to
CGB generator is not protected by87GT. In such a case voltage controlled over
current protection is provided as back up. The stators earth faults would be
covered by 64 G1 & 64G2. the earth faults in the stators winding close to natural
are generally remove, however the chances of such faults can not be ruled out. It
is therefore proposed to have at least one stators earth fault relay to detect faults
anywhere in stators winding including neutral terminal. The relay 64G1 therefore,
should be capable of detecting earth faults anywhere in the stators winding but
64 G2 may cover only 95% of the stators winding.
There are various type of relays available which operate on different principles to
detect earth faults close to neutral (64G1).
One of the type has there elements built in. One element detects rise of the
fundamental frequency voltage across the neutral grounding resistor and protects
the generator winding about 95% (relay element similar to 64G2). Second
element detects collapse of third harmonic voltage present on neutral and
thereby detects the earth fault close to neutral. Third element which supervises
PMI,NTPC 157
the voltages, prevents the tripping command to exist during generator shutdown
period. ASEA relay type RAGEA operates on as principle.
Any one the above described type of relays can be considered for 100% stators
earth fault protection. The relays are time delayed by about one second to
prevent mal operation during transformer KHV side ground faults currents is
limited to about 10A.
The earth fault relay 62 G4 shall be voltage operated inverse time relay
connected across the open delta winding of an auxiliary voltage transformer 9
(VT) on generator terminal.
The generator bus ducts has an isolated phase construction throughout and
hence cannot have a direct phase to phase fault. Their coverage by one 87GT
(and partly by 87G also in case of GCB scheme) for short circuits is therefore
considered sufficient. Earth faults in the generator bus ducts are however
covered by two protections 64G and 64 G2.
PMI,NTPC 158
In case generators have only three terminals brought out in line as well as neutral
sides (even if the stators winding is double star) it would not be possible to apply
the conventional transverse differential protection for internal faults. The inter turn
fault protection is not considered very essential since such faults are very unlikely
in single turn coil construction adopted for the large generators.
For earth fault protection of the generator rotor circuit a two stage relays (64F)
working on the principle if insulation resistance measurement of rotor is
provided. The first stage of the relay shall be connected for alarm in UCB.
Further fall in insulation resistance of the rotor circuit initiate operation of the
relay second stage which is recommended to trip the unit. However it is
recommended that the machine be shut down for detection of fault location and
rectification as early as possible on occurrence of first stage alarm because a
second earth fault at another location could be quite harmful.
PMI,NTPC 159
Transformer would also have oil level indicator with alarm contact, and devices to
detect abnormal, ties in coolers control.
A three-phase single zone impedance relay (21G) is to be provided for the back
up protection of generator against external three phase and phase to phase
faults in the EHV system, which may be hanging on due to failure of their own
system primary protection, The zone of 21G should be extend beyond the EHV
switchyard. It should be connected to trip the generator after a time delay of 1.0
to 1.5 seconds so that the generator is tripped only if the EHV line protection has
not cleared the fault even in second zone.
PMI,NTPC 160
The back up protection against resisting earth faults in the EHV system is
provided by an over current relay 51 NT connected to the current transformer
(CTs) in generator transformer HV neutral. Local breaker backup (or breaker
failure) protection 50Z is to be provided for the generator breaker EHV as well as
GCB). It would facilitate fast back up isolation of faults not cleared by the
instantaneous primary protection.
The generator can develop high over voltages in the even of mal operation of
automatics voltage regulator, or a load thrown off while generator excitation is
under manual control. An over voltage relay 59G set at 110% is to be provided to
detect its condition and give an alarm in case it persists for 2-3 seconds. The
severe over voltage would be covered by over fluxing protection which is
explained in next clause.
Over fluxing of the generator transformer and unit transformer can occur due to
over voltage on generator terminals, or due to excitation application while turbo
generator is at lower speed. Its persistence can cause gradual over heating and
damage to the generator and transformer. An over fluxing protection 99T is to be
provided to protect the generator and transformer against the condition. The
generators to be tripped if voltage/frequency remains above 1.2 p.u. for about 2-3
seconds. Time delays necessary in order to allow AVR to correct the situation. In
case of GCB scheme separate over fluxing relays need to be provided for
generator and generator transformer.
PMI,NTPC 161
Motoring of the turbine generator can occur due to storage of steam/fuel supply.
While it does not affect the generator, it can cause gradual over heating of
turbine blade. The low forward power relay 37GA along with a time delay is used
for detecting this conditions.
While reserve power relays have conventionally been used for this protection, a
low forward power relay (LFPR) is proposed to be used since both are equally
effective for this purpose. In fact LFPR is better, since turbine blade over heating
would occur even if the unit is in generating mode at a load at which LFPR
operates about 0.5% of rated output.
Any other electrical protection which have to be provided for turbine safety is the
under frequency protection. The turbine manufacturers normally stipulate
stringent limitations regarding under frequency operation of turbine, and it would
be safer to trip the unit whenever the frequency tends to drop to a value
dangerous for turbine operation.
A multi stage relay is proposed to be used for under frequency protection (81G)
the first stage of the relay gives an alarm in unit control board indicating that the
system is operating in an under frequency regime. The operator should inform
the Regional Load Dispatch Centre regarding this so that they can take timely
action by way of load shedding to improve the frequency.
The second stage will stage will again give an alarm permit operation for a set
time after which the machine will be tripped. The third stage when reached will
instantaneously trip the machine. These levels of operation are normally defined
by the turbine manufacturers. Relay are also available which have df/dt functions.
However it would also be beneficial to work out am overall operation strategy,
during under frequency conditions, in association with the Region Load Dispatch
Centre and other utilities in the region.
PMI,NTPC 162
Monitoring of generator VT fuses would also be provided to give an alarm in
UCB, in the even of fuse failure. VT fuse failure may maloperate back up
impendence stators earth fault (64G2), low forward relays and under frequency
relays therefore these protections would be blocked on VY fuse failure.
Besides the above electrical protections, the generator and its auxiliary systems
(hydrogen cooling, bearing lubrications, seal oil, gas etc.) would be protected in
accordance with manufacturers recommendation.
Fire protection system shall be provided for generator transformer and its contact
shall be give for class A tripping.
The unit auxiliary would have separate differential protection (87UT) as their
main electrical protection against phase-to-phase faults. 87UT shall also have set
instantaneous element. Earth fault bt their HV winding be covered by 64G1 and
64G2 and the earth faults in each LV winding shall be covered by restricted earth
fault protection 64 RUT. Back up to 64RUT and HT system earth faults shall be
provided by earth fault 51 NUT connected to a CT in transformer neutral. Backup
to 87 UT for transformer faults and to HT incoming breaker protections for HT
system faults would be provided by overcurrent relays 51UT with a definite time
delay to coordinate with down stream protection. Besides the above electrical
protections, the transformers would have the usual protective devices like
PMI,NTPC 163
buchholz relay with alarm and trip contacts, winding and oil temperature
indicators with alarm and devices to detect cooler abnormality. Winding
temperature indicators would have a repeater dial on UCB and will also be used
for cooler control. The H.T. bus ducts between the unit auxiliary transformer and
the associated H.T. Switchgears would also be protected by the transformer
protections 87UT, 51UT, 64NUT.
Unit auxiliary transformer is so designed that they would not normally get
overloaded. However, winding temperature indicator (WTI) and oil temperature
indicator (OTI) are provided alongwith alarm contact to detect any overloading
and annunciate.
Fire protection system shall be provided for unit auxiliary transformer and its
contact shall be given to class A tripping.
Tripping of the circuit breakers as mentioned above would suffice for electrical
isolation of the fault, the tripping of the turbine is not necessary. However, the
electrical fault which caused the tripping would require investigation, and tripping
PMI,NTPC 164
of the turbine would be required subsequently in any case. Therefore, there is no
point in trying to keep the turbine in operation after a class trip and it can also be
tripped alongwith the circuit breakers in case of class A trips. Besides the risk of
dangerous turbine over speeding upon disconnection of generator from the grid
is higher when turbine is not tripped. This risk is considerably reduced when
turbine is tripped simultaneously with circuit breakers.
Protections 64G, 21G, and 51NUT require isolation of the generator from a
persisiting external fault, for which tripping of the EHV breakers alone would
normally be sufficient. However, the fact that these ultimate back, up time
delayed protections have operated indicates a serious failure of EHV switchgear
or relays, since they would operate only if all the normal back ups EHV system
(i.e. second main protection, second zone of distance relays and local breaker)
has already failed to open (after having received a tripping command from the
bus bar differential protection or local breaker back up), in which case there
would be no point in giving another tripping impulse to the same breaker.
PMI,NTPC 165
Considering all these aspects, it is proposed that the back up protections under
consideration (46G, 21G & 51NT) be connected to initiate class A/Class A2 trip.
In case of over-fluxing, ideally only the generator excitation need to be rapidly cut
back. Since this is not feasible when AVR is not functioning properly (which is
evident from the very fact that 99T has operated), tripping of the excitation
becomes necessary. However, this would lead to loss of excitation condition
unless the generator is completely tripped at the same time. Therefore, in effect,
over-fluxing protection (99T also have to be connected to initiate tripping of all
generator circuit breakers. Considering the fact that serious abnormality in the
excitation system is indicated, and generator back in service, it is proposed that
turbine also be tripped simultaneously. 99T would therefore initiate class A/class
A2 trip.
PMI,NTPC 166
Unit Tripping Logic
The electrical fault in the generator transformer are comparatively rare, and most
of the unit tripping take place due to other causes generally related to problems
in boiler, turbine take place due to other causes generally related to problems in
boiler, turbine and their auxiliaries. For such problems, it is not necessary to trip
the generator breakers instantaneously. Infact, it is desirable to delay their
tripping, as explained below:
PMI,NTPC 167
However in case of Gas turbines, since a large compressor load is connected on
its shaft such dangerous over speeds are not expected and as such no
necessity of all the protection are connected to trip electrical breakers as well as
turbine simultaneously.
The trip contacts of WTI and OTI of generator transformer (49T), the excitation
system troubles if not urgent, and all abnormalities in generator auxiliary system
(hydrogen cooling, bearing lubrications, seal oil, gas etc.) which require unit
tripping should follow class B mode. Excitation system troubles which require
immediate tripping of excitation would initiate class A tripping. In OTI of the unit
transformer would be connected for tripping only associated H.T. circuit breakers
(but not de-enrgising the transformer.
Two separate hand reset lockout relays 86G and 186G would be provided for
class A/Class A1/Class A2 tripping. They would operate in parallel but on
separately fused 220VDC supplies, the various protections would be distributed
on these two DC supplies such that even if one of the supplies, faults. The VT
supplies, DC supplies and healthiness of lockout relays would also be monitored.
The station transformers would have differential protection (87) as main electrical
protection against phase to phase faults, 87 shall have one instantaneous high
set element. Since EHV system is solidly grounded, the HV winding earth fault
shall also be covered by 897. However, a restricted earth fault protection. Back
up to incoming breaker protection for H.T. system faults would be provided by
definite time delay over current relay (51) on all three phases on HV side of
transformer.
For earth faults in LV winding, restricted earth fault relays (64RST) shall be
provided, Backup to this and H.T. system, earth fault shall be provided by a
PMI,NTPC 168
definite time delay really (51N) connected to a CT in transformer neutral, which
shall be connected to trip EHV breaker.
Besides the above electrical protection, the transformer would have the usual
protective devices like Buchholz relay with alarm and trip contacts, winding and
oil temperature indicators with alarm and the contact, oil level, indicator with
alarm and devices to detect cooler abnormality. Winding temperature, indicator
would have a repeater dial in central control room and also be used for cooler
control.
Station transformer are so designed that they would not normally get overloaded.
However, WTI & OTI are provided alongwith alarm contact in order to detect any
over loading and annunciate.
Fire protection system shall be provided for station transformers and its contact
shall be connected to trip its EHV breaker.
PMI,NTPC 169
protection is provided for all motors, and a sensitive earth fault protection is
provided using the core balance CT on the cable.
Selection of the types relays would be based on their reliability record and ability
to work satisfactory under the prevailing environmental conditions.
For protection against phase fault, all motors up to 2000KV rating should have
instantaneous high set over current relay (50) having low transient over reach to
avoid mal operation due to DC component in motor starting current on all
phases. The motor rated above 2000KW need to be protected by high speed
differential relay (87), which would be connected to H.T. switchgear CTs on one
side and the CTs on motors natural bushings on the other side in order to have
better sensitive of the protection. Provisions of relays on all phases would give
inherent instantaneous back up for relay failure.
For protection against earth faults, all HT motors should have sensitive earth fault
relay (560N) connected o core balance (zero sequence) current transformer to
be put in H.T. switchgear. CBCT is recommended in order to have better
sensitivity of the protection for the cases where earth fault current is linked (low
resistance or high resistance grounding).
PMI,NTPC 170
For overload protection, all motors would have inverse time over current relays
(51) on two phases, and their Characteristics would be adjusted selected to lie
between the hot withstand curve and the starting curve of the motors.
The stalling or locked rotor protection will be provided only for those motors
which do not have sufficient gaps between their hot withstand and starting curves
or which have a distinct possibility of stalling. It will comprise of an over current
relay (50/LR) having plan adjustable definite time delay, which would operate in
conjunction with speed switch with adjustable setting on motor shaft.
One more over current relay (50/OL) will be provided for overload alarm, for all
motors, it would alert the operator in advance, so that corrective action may be
taken or preparations made before a motor is tripped out by the over load relays
(51) Provision of 51 on two phases and 50/OL on the third phase would provide
inherent back up against relay failure as well protection against faults near the
motor neutral which may not be detected by the other protections.
The large motors lasted above 1000KW would be having winding temperature
monitoring, with automatic scanning by the embedded RTDs. These would be
connected for alarm only winding temperature monitoring is not considered
necessary for smaller motor, which would normally be self cooled with little
possibility to overheating as long as they are not overloaded. However, adequate
monitoring of the cooling system shall be provided where water coolers are
involved.
PMI,NTPC 171
The proposed provision of CTs and connection of relays for the motors rated up
to 2000KW and for motor above 2000KW are shown in fig. 3&4 of annex-C
respectively in enclosed sketch.
Composite relays are also available which have all the features as mentioned
above. These relay are static and/or microprocessor based having built in on line
testing facilities, and have thermal memory for overload protection of motor. Such
relays, when employed, should meet the environmental conditions at their
location. Transient overreach requirement for short circuit protection and the
initial cost are some of the additional factors needing attention.
The H.T. feeders to auxiliary transformers would have instantaneous high set
overcurrent relays (50) on all phase for protection against phase to phase fault.
The LT transformers rated above 5 MVA, if any, shall be provided with differential
protection instead of short circuit protection (50). Definite time delayed low set
overcurrent relays (51) would be provided on all phases for protection against LV
side faults. The latter would also provide backup protection against faults in the
LV system. Inverse time overcurrent relays are not proposed to be used since
time varies with the fault current and low intensity faults are cleared after a
considerable time delay. Use of overcurrent relays with a definite adjustable time
delay for 51 would provide clearance of all type of faults in less than one second
(Ref. Annexure-D).
For protection against HV side earth faults, all LT transformers would have an
instantaneous earth fault relay connected to core balance CTs for all the LT
transformers.
PMI,NTPC 172
grounded) and would recover by overcurrent relays 51 mentioned in cl. No.
11.1.0. for the protection against earth faults inside the LV winding, a definite
time delayed earth fault relay is proposed which should be connected to a CT in
transformer LV neutral side. This earth faults relay shall be fully coordinated with
maximum fuse resting of outgoing motor feeders.
Besides the above electrical relays, the liquid filled LT transformers would have
Buchhloz relays (63) with alarm and trip contacts, winding and/or oil temperature
indicators with alarm and trip contacts. Dry type indoor transformers would have
only winding temperature indicator, with necessary contacts for alarm and trip.
The LT transformers normally so sized that they are not over loaded. However,
winding temperature and oil temperature are monitored and alarms are given for
temperature high in case of any overheating.
Protection of LT Motors
The 415 V motors rated above 125 KW would be controlled through circuit
breakers. They would be protected against phase-to-phase faults either with
instantaneous short circuit released in the circuit breakers, or with instantaneous
high-set over current relays (50), provided on all phases. For a sensitive earth
fault protection these motors would have instantaneous overcurrent relay (50) in
the residual CT connection.
For overload protection, the breaker controlled motors would have inverse time
overcurrent relay (51) on two phases for tripping and a definite time overcurrent
relay (50/OL) on the third phase for alarm. The arrangement would be similar to
that described earlier for the H.T. motors.
The smaller 415 V motors (rated upto 125 KW) would be controlled by
contactors. They would be protected against phase-to-phase and earth faults by
PMI,NTPC 173
HRC fuses. The fuse would be selected as not to be affected by repeated motor
starting. The overload protection would be provided with three phase thermal
(bilmetallic) overload relays.
Single phasing protection should be provided for all contactor controlled motors
which are protected by fuses. It would be ensure that this protection is not too
sensitive to negative sequence current, and is adequately stable during motor
starting, normal voltage unbalance etc.
For phase to phase faults on H.T. bus and back up protection for outgoing feeder
on these buses, a definite time delay over current relay need to be provided in all
phases on H.T. tie and incoming breakers.
Earth faults on H.T. bus and backup to all outgoing feeders on unit/station bus
would be covered by a definite time delay overcurrent relay need to be provided
in all phases on H.T. tie and incoming breakers.
For phase to phase faults on 415V incomes & buscoupler breakers. Tie to 415V
MCCs/boards, if controlled by breakers, shall also have short circuit release
fitted in the breaker. The releases shall be definite time delayed magnetic/solid
PMI,NTPC 174
state type. Definite time delayed over current relays as real so acceptable in
place of releases, Earth fault current in the 415V system would produce currents
on same magnitude as for phase to phase faults, and therefore would be covered
by phase faults relays. Earth fault protection therefore is not necessary to be
provided in incomes, buscouplers and tie feeders to MCC/board.
Time graded protect as detailed above, results in a very high operating times
(about 1.0 sec.) for relays located at income. Through switchgear have one
second through faults withstand capability, they can not be expected to withstand
internal faults for such long time without serious damage. It is therefore
recommended to adopt a reverse blocking principle to cut down the grading
times. For this arrangement all the relays as described above located on ties, bus
coupler, income, shall have instantaneous (with a short delay of about 100as)
and delayed (coordinated with downstream) stages with the instantaneous stage
of up stream blocked by all the down stream protection current element. With this
arrangement a faults last any point in the system can be detected within
100m.sec.
For phase to phase fault protection three phase high impedance differential
protection should be provided for these generators. This protection shall be
extended upto 6.6KV breaker so as to protect 6.6KV cables also, For6.6 KV bus
phase to phase faults and back pup to out-going feeders protection, voltage
controlled overcurrent relays should also be provided. Voltages control over
current relays are recommended for back protecting because fault current form
generator would reduce considerably owing to its very high steady state
impedance.
PMI,NTPC 175
detected by the voltage relay provided in the neutral VT which shall be connected
for an alarm in the central control room. Above arrangement would facilitate the
diesel generator operation under emergency conditions even if a simple earth
fault exists in the system.
PMI,NTPC 176
13. Spare Parts Management
Spare parts management is an important aspect for trouble free operation and
minimum breakdowns or shut down time in a plant. For optimizing power
generation, availability of required number of quality spare parts is of paramount
importance. While quality is normally ensured, availability is mostly poor
because of inadequate planning, Selection of spares in right quantity is equally
important, otherwise the plant may have high inventory of spares, still may not
have a needed spares. In case of NTPC; due to diversity of equipment and use
of highly abrasive coal, a large variety of spares are to be stocked. Unavailability
of even a small item could cause a total or partial unavailability of the units,
resulting into huge loss of generation and consequential industrial loss.
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The provision of 4% of equipment cost of initial spares have been found to be
inadequate and as a result, the quantity of initial spares are restricted to the
provisions made by CEA, Even though the prices quoted by vendors for
mandatory and recommended spares are very competitive since they are
subjected to bid evaluation were are not able to procure sufficient quantity of
initial spares due to financial constraints.
During initial periods, the spares parts were procured based on the
recommendations of the manufacturers who were quoting very exorbitant prices
as their virtual monopoly over these prices which were not subjected to any
evaluation.
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Since the total cost of mandatory and recommended spares has to be within the
provisions of 4% of the total equipment cost as per CEA guideline, this causes
resource constraints which result in either reduction of quantity of spares of
enhanced expenditure on spare parts.
The initial spare included essential insurance items, unit replacement and
consumable of 3 years. The period of 3 years has been chose because of non
availability of O & M personnel at site at the time of placement of order for main
equipment and long lead time associated with imported spare parts. Also no
consumption is worked out on the basis of past experience of similar equipment
and the manufactures recommendations. Any period less than 3 years of
procurement of initial spares could lead to undesirable situation of stock out.
- Self Life
- Manufactures recommendation
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- Development potential
- Consumption rate
The actual values of spares for all the packages considered together as per
past experience, works out to be in the range of 5.5 to 6% for 200MV stages
and similar trend is emerging for 500 MW sets where relatively fewer orders
have been placed so far. Since the initial spares that are being ordered
includes Insurance Spares, unit assemblies and consumable spares for
3years, it has not been possible to limit the value of initial spares within the
stipulated provision of 4% given by CEA.
NTPC being committed to high plant load factor and considering the isolated
location long lead time, multiplicity of make and type of equipment,
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sophisticated control & instrumentation and operational aids. The spares
ordered initially exceed the provision to have a sufficient stock of spares, to
avoid shortages and stock-out situations.
Based on the above experience & judicious review of initial spare parts
requirement, it has been proposed to CEA that the provision for initial spares
procurement should be as follows for both 200 MW & 500 units.
The matter is under consideration with CEA and it is hoped that as a special case
of NTPC, the provision of initial spares may be suitably enhanced.
- To procure the spare parts at the lowest individual and lowest total cycle
cost with consistency is quality.
PMI,NTPC 181
Maintenance Planning
Preventive Maintenance
During capital repairs and major overhauls, many items are required to be
changed depending upon the wear and tear, failure and past history of the
equipment. Theses items are normally long lead items and hence a
comprehensive planning for such spares should be done at least 2-3 years in
advance to meet the overhauling requirements. 5year rolling plans for stations
should be prepared, updated and reviewed every year for the purpose of
PMI,NTPC 182
ascertaining the need of spares, depending upon the plan condition and
equipment behaviour.
Break-down Maintenance
It is very different to predict the requirement of spares for such jobs as the
pattern of breakdown occurrence is uncertain. However based on regular
condition monitoring predictions can be made Regarding residual life of the
equipment. Accordingly, requirement of spares can be worked out for future
period depending upon past history and failures.
Since there is always some gap between the time when order is placed and the
spare is actually reviewed, the role of spares planning is very vital. The planning
cycle and inventory level fixation depends upon various factors.
Location of the plant The location of the plant effects the lead
time & local source development. NTPC
plants located at remote place have to
carry high inventory of spares.
PMI,NTPC 183
Nature of spares Proprietary items or imported spares
which calls for cumbersome import
procedure, have high lead periods and
should be planned well in advance.
PMI,NTPC 184
Analysis and Classification
F.S.N. Analysis The spares are classified into Fast, Slow and
non moving categories based on the movement rate.
Fast Moving Items which have moved at least once in 1-2 years
Slow Moving Items which moved at least once in 2-4 years.
Non Moving Items which have not even once in 4-5 years.
Type of Spares:
Insurance Spares The spares which normally not required but are
vital for the equipment as in case of any miss hope or
accidents non availability of these items will lead to
long out ages. For example turbine rotors exciters etc.
Consumable Spares These are fast wearing out items and have reduced
life. These spares are replaced.
Non-Moving Items
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A. Contributing to 60-80% of total spares consumption. Industrial annual
consumption Of more than 50 thousand.
PMI,NTPC 186
Easy These items can be procured from standard suppliers
in a short lead time.
Inventory Control
Based on the VBC and ABC analysis, a confidence level matrix have been
adopted to determine the safety stock of the spares.
Confidence matrix
A B C
V 85% 95% 99%
K=1 K=1.7 K=2.5
E 75% 85% 95%
K=0.75 K=1.0 K=1.7
D 70% 76% 80%
K=0.7 K=0.75 K=0.8
The spare parts planning and forecasting is proposed to be done on fixed review
period basis. It is envisaged that all the consumables spares will be reviewed
only once in a years. A calendar for the review of spares have been prepared
which provides review of spares segregated into seven packages such as SG,
TG, Elect., C&I, Off-sites etc. Apart from these, high consumption critical spares
PMI,NTPC 187
of Bowl mills, coal handling plant and ash handling plants will be reviewed on
quarterly basis.
The maximum inventory level has been fixed on the basis of consumption rate,
lead time and safety stock.
A. Lead period
i) BHEL spares = 1.5 years 2 years
ii) Other than BHER = 1 year
3. Safety stock
4. maximum Level
= lead period consumption stock + review period Safety Stock
5. Reorder quantity
PMI,NTPC 188
N.B in case the present stock is less than lead period consumption , recorder
quantity should be taken equal to review period consumption only.
Cost reduction
Alternative source
Import substitution
Availability
Reduction in Lead time
It has been proposed that items which are common to 2 or more than projects or
which have a annual consumption value of more than 10 lakhs will be taken up
for developments from Corporate Centre while the items having less
consumption value or particular to individual projects will be taken up for
development by project itself. The responsibility of preparation of drawings and
technical specification will be O&M planning at Sites and COS at Corporate
Centre while replacement of order will be the responsibility of site materials
Deptt. And Materials department at projects and Coordinate Centre respectively.
Once the source standardisation is done, projects can place order on these
parties for their annual requirements.
PMI,NTPC 189
Already the jobs of spare parts developments has been taken up by all the
projects & coordinate Centre with encouraging results and the number of spare
parts developed will increase with the availability of drawings and material
specification of spares which is a very elaborate process.
Vender development
- Spares for which there is not enough capacity witmn the country though
the required specifications are available
A study conducted shows that the category(b) constitutes about 80% of the
total import budget of spare and thus requires special attention towards import
substitution drive. We had developed in our project many of the spares which
would lead to foreign exchange savings to the tune of several lack per annum.
PMI,NTPC 190
accordingly enlisting successful vendors for such development items and
continue to explore new competent sources.
Identification of Sources
Information obtained from DGTD regarding items licensed for same/ allied
items.
PMI,NTPC 191
Magazines like Industrial /Electronic product finders, Computers Todays,
Industrial Equipment News, National Product News, Telemetric India, etc.
Registration of Vendors
Vendors registered with DGTD/NSIC and known to NTPC site/OS need not
be reassessed
Enquiries
Enquiries can be floated for spare development to all the registered vendors for
similar items. In case more than one vendor is not available in the approved
vendor list for a particular item, enquiry can also be floated even to single vendor
with approval.
PMI,NTPC 192
The committee can propose to issue more than one PO against single item in
case of multiple offers (all being L1).
PMI,NTPC 193
14. Date Sheet for Gas Projects
S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR
2. Fuel & its Source Natural Gas Natural Gas Natural Gas Natural Gas Natural Gas From
tapped from tapped from /NGL Natural from BHEL Gandhar Gas Basin.
HBI pipeline HPI pipeline Gas is supplied pipeline.
From HBJ
3. Gas Requirement 1.75 MCMD 2.25 MCMD 2.25 MCMD 3MCMD 1.5MCMD
(Annual Average) (Annual Average) (Annual Average) (Annual Average) (Annual Average)
4. Water Source Kota right main Etawah branch Hazira Branch Net Canal Wareada river
canal canal canal
5. Condenser cooling system Hybrid (Closed Closed circuit Closed Circuit Closed Circuit Closed Circuit
circuit/once through)
6. Mode of operation of plant Base load and/or Base load and/or Base load and/or Base load and/or Two shift operation
two shift or peak- two shift or peaking shift or peaking or two shfit or
ing duty depending duty depending on duty depending peaking duty
on technical and/ technical and/ on technical and/ depending on
economic conside- economic economic technical and/
rations consideration consideration economic
consideration.
7. Main Plant awarded on ABB, West MHI Japan GEC-Alsthom Siemen AG, West Marubani,
Germany on on 03.09.90 France on Germany Corporation
20.8.87 05.03.90 on 26.3.92
8. Orientation of GT Exhaust Axial Axial Axial Axial Axial
PMI,NTPC 194
S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR
9. Design Conditions 270C asb. Temp. 270C asb. Tmep. 60% 270C asb. Tmep. 60% 270C asb. Tmep 270C asb. Tmep.
60% RH 253 M RH, 140M above sea 60% RH, 5.5 M above 60% RH 210 M 60%RH, 23.25M
above seal level, Level, 320C CW temp. sea level, 320C CW above sea 320C above seal level,
320C CW temp. temp. CW temp. 320C temp.
10. Manufacturer ABB, Germany MHI, Japan Eropean Gas Turbine Siemens AG, ABB, Germany
France Germany.
11. ISO base rating at 98.9 121.51 116.9 142.42 147.8
12. Net O/C base output of GT 89.25 111.76 105.62 131.31 131.36
at design condition (MW)
13. Net O/C heat rate at base 2770 2623 2697 2692 2617
load and design conditions
(K cal/Kg. Hr.)
14. Net efficiency of GT (%) 31 32.78 31.9 31.95 32.8
(O/C, at base load, design
conditions)
15. Natural gas consumption 6.76 8.2 7.8 9.6 9.4
(O/C, base load design
condition kg/sec, assuming
cal value of gas as 8700
K cal/m3 and density of gas
As 0.856 kg/m3
16. Turbine speed (rpm) 3000 3000 3000 3000 3000
17. Compression 12.4 13 12 10.2 14.3
18. Air bass flow (O/C base 370 412 388 462 500
19. Exhaust gas temp. (0C) 505 513 540 560 525
PMI,NTPC 195
S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR
22. start-up mechanism frequency Converter Starting motor Starting motor Frequency Converter Frequency converter
DESIGN FEATURES
BYPASS DAMPER
29. Type Diverter type Diverter Louver Diverter type Diverter Louver Diverter type
WHRB
30. Type Forced circulation/ Forced circulation/ Forced circulation/ Forced circulation/ Natural circulation/
Dual Pressure Dual Pressure Dual Pressure Dual Pressure Dual Pressure
PMI,NTPC 196
S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR
31. Manufacturer Wanger Biro/Austria MHI. Japan CMI. Belgium BHEL, India KHI, Japan (with
(with Wagener Henry vogt design)
Biro design)
a) HP Super heater
Out let temp. (0C) 485 495 520 530 504.5
Outlet pressure (bar) 63.97 60 70 65 76.9
b) LP Drum/Super heater
Out temp. (0C) 210 158.1 193.2 200 220
Outlet Pressure 5.91 bar 7 kg/cm2 7 bar 5.7 bar 6.1 bar
STEAM TURBINE
32. Make ABB, Germnay MHI, Japan ALSTHOM, France BHEL, India ABB, Germany
33. Type Tandem compound Tandem compound Tandem compound Tandem compound Tandem compound
Dual pressure Dual pressure Dual pressure Dual pressure Dual pressure
Condensing type Condensing type Condensing type Condensing type Condensing type
34. Mode of Operation Sliding Pressure Sliding Pressure Sliding Pressure Sliding Pressure Sliding Pressure
35. HP CYLINDER Single flow Single flow Single flow Double flow Single flow
25 Stages 25 stages (Impulse) 13 Stages 24 Stage (Reaction) Single flow
Impulse
36. LP CYCLINDER Double Flow Double Flow Double Flow Double Flow Double Flow
6 stage (Reaction) 6 stages (Reaction) 5 stage (Reaction) 7 stage (Reaction)
38. Based load out put at 153.28 MW 109.3MW 116.1 MW 154.51 MW 227 MW
PMI,NTPC 197
S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR
40. Condenser back pr. At 100 bar 72mm hg abs 92 a bar 0.1122 kg cm2 100a bar
load and design condition.
41. Cooling water flow 29700 M3/hr 23340M3/hr 23061 M3/hr 25000 M3/hr 37728 M3/hr
42. Design Cooling water temp. 320C 320C 320C 320C 320C
DEAERATOR
43. No. of Deaerator/module one (1) one (1) one (1) one (1) one (1)
PMI,NTPC 198