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Report on Industrial Training

GAS TURRBO POWER STATION

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REPORT ON
INDUSTRIAL TRAINING
AT
GAS TURBO POWER STATION
VIJJESWARAM

Submitted in Partial Fulfillment of the

Requirement for Award of the Degree
Of

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING

By
Yaswanth Pavan Kumar Akula
(11701955)

Under the Guidance of

Shri Ch.N.Pulleswara Rao

DEPARTMENT OF MECHANICAL ENGINEERING

LOVELY PROFESSIONAL UNIVERSITY
PHAGWARA, PUNJAB (INDIA) -144402
2019

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Lovely Professional University Jalandhar, Punjab

CERTIFICATE

I hereby certify that the work which is being presented in the industrial summer training entitled “APGPCL”
in partial fulfillment of the requirement for the award of degree of Bachelor of Technology and submitted
in Department of Mechanical Engineering, Lovely Professional University, Punjab is an authentic record of
my own work carried out during period of summer training under the supervision of Industry supervisor
Shri Ch.N.Pulleswara Rao, Manager, Department of “Mechanical Engineering” “APGPCL”,

The matter presented in this summer training has not been submitted by me anywhere for the award
of any other degree or to any other Institute.

Date: 04 july 2019 Yaswanth Pavan Kumar Akula

This is to certify that the above statement made by the candidate is correct to best of my knowledge.

Date: 04 july 2019 N.pulleswara Rao

Industry Supervisor

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ACKNOWLEDGEMENT

It is always a pleasure to remind the fine people in the Engineering program for their

sincere guidance I received to uphold my practical as well as theoretical skills in

engineering.

Firstly I would like to thank ( HOD of Mechanical Engineering) for meticulously

planning academic curriculum in such a way that students are not only academically

sound but also industry ready by including such industrial training patterns.

I express my immense pleasure and deep sense of gratitude to Shri M.Chitti Babu,

General Manager (APGPCL, Vijjeswaram) for giving me this valuable opportunity to

undergo industrial training in GTPS to enhance my theoretical knowledge and Shri Ch. N

Pulleswara Rao, Manager (Mechanical Department, OMS) for guiding me through out the

length of the training .

Finally, I would also like to thank all the staff of operations, mechanical and I&C

departments for their encouragement and support during the course of the training.

Yaswanth pavan kumar Akula

11701955
M1751
School Of Mechanical Engineering

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STUDENT DECLARATION

I, Yaswanth Pavan Kumar Akula, hereby declare that the presented report of internship titled “GAS
TURBO POWER STATION” Of “ APGPCL” (Vijjeswaram)is uniquely prepared by me after the
completion of one month internship at APGPCL Ltd.

I also confirm that ,the report is only prepared for my academic requirement not for any other purpose .
It might not be used with the interest of opposite party of the corporation.

Yaswanth Pavan Kumar Akula

11701955
M1751
School Of Mechanical Engineering

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CONTENTS
1. Introduction

1.1 Electricity and India

1.2 A brief introduction about GTPS

2. Electricity Production through gas

2.1 Simple Cycle

2.2 Combined power Cycle
2.3 Components of a Combined Cycle Power Plant

3. Gas Turbines

3.1 Introduction
3.2 Components of Gas Turbines
3.3 Simple Gas Turbine
3.4 Classification of Gas Turbines
3.5 Factors effecting performance
3.6 Performance Enhancement
3.7 Performance Degradation
3.8 Advantages
3.9 Gas Turbines At GTPS

4. Heat Recovery Steam Generator

4.1 Introduction
4.2 Classification
4.3 Components

5.Steam Turbines

5.1 Introduction
5.2 Components

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INTRODUCTION
1.1 Electricity and India :

 The utility electricity sector in India has one national grid with an installed capacity of
357.875 GW as of 30 June 2019.

 Renewable power plants, which also include large hydroelectric plants, constitute 34.86% of

India's total installed capacity.

 During the 2017-18 fiscal year, the gross electricity generated by utilities in India was

1,303.49 TeraWatt hour and the total electricity generation (utilities and non utilities) in the country

was 1,486.5 TWh.

 The gross electricity consumption during the 2017-18 fiscal year was 1,149 kWh per

capita.

 India is the world's third largest producer and third largest consumer of electricity. In the 2015-

16 fiscal year, electric energy consumption in agriculture was recorded as being the highest (17.89%)

worldwide.

 The per capita electricity consumption is low compared to most other countries despite India

having a cheaper electricity tariff.

 The most serious issue India must address is that the gap between energy demand and energy supply

is wide and growing.

 Two reasons for this trend are demographics and economics: not only is India’s economy growing,

thereby demanding more energy and electricity, but the population is as well.

 There is also massive urbanization, which is putting more pressure on energy and the environment.

 India’s power network comprises five regions spanning the country.

 While each is connected with a neighbouring region, there are inadequate inter- regional connections

through high voltage transmission lines, creating difficulties for moving power from electricity

surplus states to those in shortage.

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 This also creates difficulties on a seasonal basis, as power is often in short supply during the dry
season and abundant in some regions during the monsoon but cannot be moved to help other states.

 The following table gives the details of electricity production in India during the last 72 years.

Growth of Installed Capacity in India

Thermal (MW)
s.no

Installed Capacity Nuclear

as on Sub- (MW)
Coal Gas Diesel Total Hydro
Thermal

1 31-Dec-1947 756 - 98 854 - 508

2 31-Dec-1950 1,004 - 149 1,153 - 560

3 31-Mar-1956 1,597 - 228 1,825 - 1,061

4 31-Mar-1961 2,436 - 300 2,736 - 1,917

5 31-Mar-1966 4,417 137 352 4,903 - 4,124

6 31-Mar-1974 8,652 165 241 9,058 640 6,966

7 31-Mar-1979 14,875 168 164 15,207 640 10,833

8 31-Mar-1985 26,311 542 177 27,030 1,095 14,460

9 31-Mar-1990 41,236 2,343 165 43,764 1,565 18,307

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Growth of Installed Capacity in India

Thermal (MW)
s.no

Installed Capacity Nuclear

as on Sub- (MW)
Coal Gas Diesel Total Hydro
Thermal

10 31-Mar-1997 54,154 6,562 294 61,010 2,225 21,658

11 31-Mar-2002 62,131 11,163 1,135 74,429 2,720 26,269

12 31-Mar-2007 71,121 13,692 1,202 86,015 3,900 34,654

13 31-Mar-2012 112,022 18,381 1,200 131,603 4,780 38,990

14 31-Mar-2017 192,163 25,329 838 218,330 6,780 44,478

15 31-Mar-2018 197,171 24,897 838 222,906 6,780 45,293

16 31-Mar-2019 200,704 24,937 637 226,279 6,780 45,399

1.2 Brief introduction about GTPS, Vijjeswaram :

 GTPS, Gas turbo power station, vijjeswaram is the first gas based power generating plant in south
India.

 It is located on the left flank of Sir Arthur Cotton Barraige on the western side of the river Godavari.

 It is a joint sector plant owned by AP Gas Power Corporation ltd and many other private sector
companies.
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 It consists of two stages i.e. Stage-I & Stage-II with a total capacity of 272 MW i.e. 100 MW& 172
MW respectively and both the stages are installed as combined cycle plants of both gas and steam
turbines.

 Stage-l was setup during the years 1990-92 with a capacity of 100MW, comprising 2 x 33 MW Gas
Turbines and 1 x 34 MW Steam Turbine.

 This is the first gas based power plant in South India. Stage-II with installed capacity of 1x112MW
Gas turbine and 1x60 MW steam turbine was commissioned during 1997-98.

 This has provision to run with 100% natural gas or dual fuel i.e…, natural gas with Naphtha.

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2. Electricity production through Gas

Generally, electricity production using gas is done using two different power cycles

 Simple Cycle
 combined Power Cycle

2.1 Simple Cycle :

 When a gas turbine is arranged to operate in simple cycle mode, air is drawn in from the
atmosphere, compressed, heated by combustion with a fuel and expanded through the turbine.

 The mechanical power generated as a result of rotation of the turbine is used to drive an electrical
generator and the hot gases are exhausted to the atmosphere.

 Figure 1 ,The connection between the turbine and the driven machine may be through direct coupling
of the drive/ driven machine shafts, or through a speed adjustment gearbox.

 Since the electrical generator speed is normally kept constant, the direct coupling is usually used for
the larger power generation machines in order to optimize the mechanical efficiency.

Figure 1

 The simple cycle arrangement is often used for small installations, or in areas where there is a large
demand for power and fuel prices are low.

 However, owing to its low fuel to electricity efficiency (30–35%), its use is not common in the
industry.

 Improvements to this efficiency can be made through recovering some of the heat in the gas exhaust
and using it to preheat fuel or inlet air.

 Developments have led to other uses for the hot exhaust gas streams and the 'combined cycle'
arrangement

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2.2 Combined Power Cycle :

 The process for converting the energy in a fuel into electric power involves the creation of
mechanical work, which is then transformed into electric power by a generator.

 Depending on the fuel type and thermodynamic process, the overall efficiency of this
conversion can be as low as 30 percent.

 This means that two-thirds of the latent energy of the fuel ends up wasted. For example,
steam electric power plants which utilize boilers to combust a fossil fuel average 33 percent
efficiency.

 Simple cycle gas turbine (GTs) plants average just under 30 percent efficiency on natural gas,
and around 25 percent on fuel oil. Much of this wasted energy ends up as thermal energy in
the hot exhaust gases from the combustion process.

 To increase the overall efficiency of electric power plants, multiple processes can be
combined to recover and utilize the residual heat energy in hot exhaust gases. In combined
cycle mode, power plants can achieve electrical efficiencies up to 60 percent.

 The term “combined cycle” refers to the combining of multiple thermodynamic cycles to
generate power.

 Combined cycle operation employs a heat recovery steam generator (HRSG) that captures
heat from high temperature exhaust gases to produce steam, which is then supplied to a steam
turbine to generate additional electric power.

 The process for creating steam to produce work using a steam turbine is based on the
Rankine cycle.

 The most common type of combined cycle power plant utilizes gas turbines and is called a
combined cycle gas turbine (CCGT) plant.

 Because gas turbines have low efficiency in simple cycle operation, the output produced by
the steam turbine accounts for about half of the CCGT plant output.

 There are many different configurations for CCGT power plants, but typically each GT has
its own associated HRSG, and multiple HRSGs supply steam to one or more steam turbines.

 For example, at a plant in a 2x1 configuration, two GT/HRSG trains supply to one steam
turbine; likewise there can be 1x1, 3x1 or 4x1 arrangements.

 The steam turbine is sized to the number and capacity of supplying GTs/HRSGs. In GTPS
both the stages use combined cycle to generate electricity.

 In Stage - I exhaust from both the gas turbines is collected and is used to produce steam
which is used to run the steam generator.

 The same happens in stage - II with the one gas turbine present there.

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2.3 Components of a Combined Cycle Power Plant

 Electricity generation in a Combined cycle power plant happens in two steps …

1. Gas turbine Generator

2. Heat Recovery Steam Generator (ḪRSG)

Figure 2

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3 .GAS TURBINES

3.1 Introduction :

 Gas turbine is rotary type of I.C. engine. The cyclic events of gas turbine are similar to reciprocating
type I.C. engine, but each event in the gas turbine is carried out in different devices.

 A simple gas turbine is comprised of three main sections a compressor, a combustion chamber, and
a power turbine. The gas-turbine operates on the principle of the Brayton cycle, where compressed
air is mixed with fuel, and burned under constant pressure conditions.

 The resulting hot gas is allowed to expand through a turbine to perform work. In a 33% efficient
gas-turbine approximately two / thirds of this work is spent compressing the air, the rest is available
for other work i.e. (mechanical drive, electrical generation).

 The air is first compressed in a rotary compressor before passing to combustion chamber where fuel
is injected and ignited. The hot burnt gases expand through the blades of a turbine where the kinetic
energy of burnt gases is utilized to produce power.

 Finally the gases are exhausted from the turbine unit. The part of power developed is used to drive
the compressor, thus the overall efficiency of the gas turbine unit is lowered. Gas turbines are
comparatively small weight and size as that of steam turbines.

3.2 Components Of Gas Turbine :

There are three main components in any Gas turbine. They are:

1. Compressor

2. Combustion Chamber

3. Turbine
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1. Compressor :

 Air is drawn into the compressor via guide vanes and flows in the direction of the shaft axis
through several rows of stationary vanes (stators) and rotating blades (rotor buckets).

 Each vane/blade set is known as a compressor stage and serves to progressively increase air
pressure as it passes from stage to stage.

Fig 3: Compressor

2. Combustion Chamber :

 Within the combustion chamber the compressed air is mixed with vaporized fuel and the mixture is
burned.
 This creates products of combustion that are at a higher temperature than the compressed air and is
used to do more work than the energy used in compressing the air.

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3.Turbine :

 The hot, high pressure products of combustion are passed to the turbine where they are
allowed to expand through several rows of alternate stationary vanes and rotating blades.

 Each vane/blade set is known as a turbine stage, and as the mixture accelerates past each
stage, the kinetic energy within the expanding gas is converted into rotational energy using
the rotor blades.

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3.3 Simple Gas Turbine :

 A schematic diagram for a simple-cycle, single-shaft gas turbine is shown in figure - 6.

 Air enters the axial flow compressor at point - 1 at ambient conditions. Air entering the compressor
at point- 1 is compressed to some higher pressure.

 No heat is added; however, the temperature of the air rises due to compressio00n, so that the air at
the discharge of the compressor is at a higher temperature and pressure

 Upon leaving the compressor, air enters the combustion system at point-2, where fuel is injected and
combustion takes place.

 The combustion process occurs at essentially constant pressure. Although very high local
temperatures are reached within the primary combustion zone (approaching stoichiometric
conditions), the combustion system is designed to provide mixing, burning, dilution, and cooling.

 Thus, by the time the combustion mixture leaves the combustion system and enters the turbine at
point-3, it is a mixed average temperature.

 In the turbine section of the gas turbine, the energy of the hot gases is converted into work. This
conversion actually takes place in two steps.

 In nozzle section of the turbine, the hot gases are expanded and a portion of the thermal energy is
converted into kinetic energy.

 In the subsequent bucket section of the turbine, a portion of the kinetic energy is transferred to the
rotating buckets and converted to work.

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 Some of the work developed by the turbine is used to drive the compressor, and remainder is
available for useful work at the output flange of the gas turbine.

 Typically, more than 50% of the work developed by the turbine sections is used to power the axial
flow compressor.

3.4 Classification of Gas Turbines :

 Gas turbines are classified as follows :

1. According to path of working fluid:

a) Open-cycle gas turbine
b) Closed-cycle gas turbine

2. According to basis of combustion process:

a) Constant pressure type gas turbine
b) Constant volume type gas turbine

3.4.1 Open - Cycle Gas Turbine

 The rotary compressor takes in air from atmosphere and raises the pressure to required level.

 The compressed air from compressor enters combustion chamber where it mixes with fuel, and
ignition takes place at constant pressure.

 The hot gases expands through turbine blades producing power, after expansion gases are exhausted
into atmosphere.

 Part of the turbine power is used to drive the compressor and remaining is utilized to generate
electricity.

 Open gas turbine cycle is the most basic gas turbine unit. The working fluid does not circulate
through the system, therefore it is not a true cycle.

 It consists of a compressor, a combustion chamber and a gas turbine.

 The compressor and the gas turbine are mounted on the same shaft. The compressor unit is either
centrifugal or axial flow type.

3.4.2 Closed - cycle Gas Turbine :

 In this case the same working fluid (air) is continuously circulated. Air is first compressed
adiabatically in a compressor and high compressed air enters the heat exchanger where air is heated
at high pressure by external source.

 Here air is not in direct contact with fuel i.e., air is not in contact with products of combustion. Hot
air is now expanded adiabatically through turbine blades producing power.

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 The air leaving the turbine enters the coolers where it is cooled to initial temperature by circulating
cooling water. Cooled air is recirculated to the compressor and the cycle is repeated.

3.5 Factors effecting performance of Gas :

 Turbine Since the gas turbine is an ambient air-breathing engine.

 Its performance will be changed by anything affecting the mass flow of the air intake to the
compressor, most obviously changes from the reference conditions of 59°F (15°C) and 14.7 PSIA
(1.013 bar).

 Figure 8 illustrates how ambient temperature affects output, heat rate, heat consumption, and exhaust
flow for Frame 9E 03 gas turbine manufactured be “General Electric” present at GTPS, Vijjeswaram.
Each turbine model will have its own temperature-effect curve, as it depends on the cycle parameters
and components efficiencies as well as air mass flow.

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 Correction for altitude or barometric pressure is more straightforward.

 The less dense air reduces the airflow and output proportionately heat rate and other cycle parameters
are not affected.

 Similarly, moist air, being less dense than dry air, will also have an effect on output and heat rate. In
past, this effect was thought to be too small to be considered.

 However, with the increasing size of gas turbines and utilization of humidity to bias water and steam
injection for NOx control, this effect has greater significance.

 It should be noted that this humidity effect is a result of the control system approximation of firing
temperature used on GE heavy-duty gas turbines.

 Single shaft turbines that use turbine exhaust temperature biased by compressor discharge pressure
will reduce power as a result of ambient humidity because the density losses due to compressor inlet
air temperature.

 The control system is set to follow the inlet air temperature function. Inserting air filtration,
silencing, evaporative coolers, chillers in the inlet, or exhaust heat recovery devices causes pressure
losses in the system.

 The effects of these pressure losses are somewhat unique to each design.The effect of humidity is
given by the following graph.

 Fuel type will also impact performance. The natural gas produces more output than does distillate oil.

 This is due to the higher specific heat in the combustion Products of natural gas, resulting from the
higher water vapor content produced by the higher hydrogen/carbon ratio of methane.
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 As a result of these influences, each turbine model will have some application guidelines on flows,
temperatures, and shaft output to preserve its design life.

 In most cases of operation with lower heating value fuels, it can be assumed that output and
efficiency will be equal to or higher than that obtained on natural gas.

 In the case of higher heating value fuels, such as refinery gases, output and efficiency may be equal
to or lower than that obtained on natural gas.

3.6 PERFORMANCE ENHANCEMENTS:

 Generally, controlling some of the factors that affect gas turbine performance is not possible.

 Most are determined by the planned site location and the plant configuration, i.e., simple- or
combined-cycle.

 In the event additional output is needed, several possibilities to enhance performance may be
considered .

3.6.1 Inlet Cooling :

 The ambient effect curve (Figure 8) clearly shows that turbine output and heat rate are improved as
compressor inlet temperature decreases.

 Lowering the compressor inlet temperature can be accomplished by installing an evaporative cooler
or Inlet chiller in the inlet ducting downstream of the inlet filters.

 Careful application of these systems is necessary, as condensation or carryover can exacerbate

fouling and degrade performance.

 Generally, such systems are followed by compressor the moisture separators or coalescing pads to
reduce possibility of moisture carryover.

 As Figure 12 shows, the biggest gains from evaporative cooling are realized in hot, low - humidity
climates.

 It should be noted, from Figure 12, that evaporative cooling is limited to ambient temperatures of 59
F/150 C and above because of potential for icing the compressor.

 Information contained in Figure 12 is based on an 85% effective evaporative cooler. Effectiveness is

of how close the cooler exit temperature approaches the a measure ambient wet bulb temperature.

 For most applications, coolers having an effectiveness of 85% or 90% provide the most economic
benefit.

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Fig 12 : Effect of evaporative cooling on heat rate and output

 Chillers, unlike evaporative coolers, are not limited by the ambient wet bulb temperature.

 The achievable temperature is limited only by the capacity of the chilling device to produce
coolant and the ability of the coils to heat. initially follows a line of constant specific
humidity(Figure 13).

 As saturation is approached, water begins to condense from the air, and mist eliminators are used.

 Further heat transfer cools the condensate and air, and causes more condensation.

 Because of the high heat of vaporization of water, most of the cooling energy in this regime goes
to condensation and little to temperature reduction.

Fig 13 : Inlet Chilling Process

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3.6.2 Steam and Water Injection for Power Augmentation

 Injecting steam or water into the head end of the combustion chamber for NOX abatement increases
mass flow and, therefore, output.

 Generally, the amount of water is limited to the amount required to meet the NOX requirement in
order to minimize operating cost and impact on inspection intervals .

 Steam injection for power augmentation has been an available option on GE gas turbines for over 30
years.

 When steam is injected for power augmentation, it can be introduced into the compressor discharge
casing of the gas turbine as well as the combustion chamber.

 The effect on output and heat rate is the same as that shown in the Figure 14.

 GE gas turbines are designed to allow up to 5 of the compressor airflow for steam injection to the
combustion chamber and compressor discharge.

 Steam must contain 50 F/28 c super heat and be at pressures comparable to fuel gas pressures .

 When either steam or water is used for power augmentation, the control system is normally designed
to allow only the amount needed for NOX abatement until the e machine reaches base load.

 At that point, additional steam or water can be(full) admitted via the governor control.

3.7 PERFORMANCE DEGRADATION :

 All turbo machinery experiences losses in performance with time. Gas turbine performance
degradation can be classified as recoverable or non- recoverable loss.

 Recoverable loss is usually associated with compressor fouling and can be partially rectified
by water washing or more thoroughly, by mechanically cleaning the compressor blades and
vanes after opening the unit.

 Non-recoverable loss due primarily to increased turbine and compressor clearances and
changes in surface finish and air foil contour.

 Because this loss is caused by reduction in efficiencies, it cannot be recovered by operational

procedures, external maintenance or compressor cleaning, but only through replacement of
affected parts at recommended inspection intervals.

 Quantifying performance degradation is difficult because consistent, valid field data is hard to
obtain.

 Correlation between various sites is impacted by variables such as mode of operation,

contaminants in the air, humidity, fuel and diluent injection levels for NOX Another problem
is that test instruments and procedures vary widely, often with large tolerances.

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 Typically, performance degradation during the first 24,000 hours of operation(the normally
recommended interval for a hot gas path inspection) is 2% to 6% from the performance test
measurements when corrected to guaranteed conditions.

 This assumes degraded parts are not replaced. If replaced, the expected performance
degradation is 1% to 1.5%.

 Recent field experience indicates that frequent off-line water washing is not only effective in
reducing recoverable loss, but also reduces the rate of non- recoverable loss.

 One generalization that can be made from The data is that machine located in 3 dry, hot
climates typically degrade less than those in humid climates.

3.8 Advantages of Gas Turbine :

1. Equipment Cost :

 The basic cost of a gas turbine-based power plant is significantly less than similar sized alternatives,
such as conventional coal or oil fired facilities.

 As an example, the cost per installed kilowatt (kW) for a gas turbine based plant is in the region of
$200 to $350 compared with $750 to $1,000 for a conventional coal-fired plant.

2. Lead Time :

 The time from placement of order to final commissioning of a gas turbine based power plant can be
significantly shorter than similar sized alternatives.

 As an example, construction of a simple cycle gas turbine based plant can take as little as 12 months,
compared with three to five years for a conventional coal-fired plant.

3. Efficiency :

 Gas turbine based power plants can be extremely efficient depending on the design and arrangement
of the equipment. Fuel to electricity efficiencies of 55–60% are achievable compared with a norm of
35–38% for conventional coal-fired plant.

4. Environmental Impact :

 Gas turbine based plant has much less impact on the environment than similar sized alternatives.
Emissions of harmful gases and particulates are significantly lower than conventional coal-fired
plants, and their physical size is also small since there is no need for large civil works, extensive fuel
stock piles, ash dumps etc.

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3.9 Gas Turbines At GTPS :

 At GTPS there are a total of 3 gas turbines(2 in stage - I and 1 in stage - II)
 The following table gives their specifications. …..

Stage-1 Stage -2

N.o of Gas Turbines 2(2*33MW) 1(112MW)

Model GE Frame 6B GE Frame 9E
Control System MARK-4 MARK-6
Compressor Stages 17 17
Turbine Stages 3 3
Shaft Rotation Speed 5100 RPM 3000 RPM
Load Gear Box Available Available
Starting Device Diesel engine Electrical starting motor
Fuel Natural Gas Natural gas and naptha
(dual fuel system)

Why use a Load gear box ?

 The diesel engine is used to provide the starting torque for gas turbine, while firing takes place in
combustion chamber.

 This diesel engine accelerates the turbine shafts to high speeds which are far greater than the
generator rated speed.

 In order to regulate this excess speed and to bring the generator to run at its rated speed, a load gear
box is used.

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4 HEAT RECOVERY STEAM GENERATOR

4.1 Introduction :

 The HRSG is basically a heat exchanger, or rather a series of heat exchangers.

 It is also called a boiler, as it creates steam for the steam turbine by passing the hot exhaust gas flow
from a gas turbine or combustion engine through banks of heat exchanger tubes.

 The HRSG can rely on natural circulation or utilize forced circulation using pumps.

 As the hot exhaust gases flow past the heat exchanger tubes in which hot water circulates, heat is
absorbed causing the creation of steam in the tubes.

 The tubes are arranged in sections, or modules, each serving a different function in the production of
dry super-heated steam.

 These modules are referred to as economizers, evaporators, super-heaters/ reheaters and preheaters.

4.2 Classification of HRSG :

 Modular HRSGs can be categorized by a number of ways such as direction of exhaust gases flow or
number of pressure levels.

 Based on the flow of exhaust gases, HRSGs are categorized into vertical and horizontal types.

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 In horizontal type HRSGs, exhaust gas flows horizontally over vertical tubes whereas in vertical
type HRSGs, exhaust gas flow vertically over horizontal tubes.

 Based on pressure levels, HRSGs can be categorized into single pressure and multi pressure. Single
pressure HRSGs have only one steam drum and steam is generated at single pressure level whereas
multi pressure HRSGs employ two (double pressure) or three (triple pressure) steam drums.

 As such triple pressure HRSGs consist of three sections: an LP (low pressure) section, a reheat/IP
(intermediate pressure) section, and an HP (high pressure) section.

 Each section has a steam drum and an evaporator section where water is converted to steam.

 This steam then passes through super heaters to raise the temperature beyond the one at the
saturation point.

 GTPS employs a horizontal multi-pressure (double) HRSG in both Stage - I and Stage - II

4.3 Components Of an HRSG :

 The various components of HRSG are explained below

Evaporator section:

 This is the most important section of HRSG.

 In this section the water gets evaporated to steam. This section consists of coils in which water is
passed, and these coils are surrounded by exhaust gas released by the gas turbine.

 The heat transferred is enough to evaporate the water to steam and thus the steam is generated in an
evaporator .

Super heater section :

 The Super heater section of HRSG is used to dry the saturated vapour being separated in the steam
drum.

 In some units it may only be heated to little above the saturation point wherein other units it may be
super-heated to significant temperature for additional energy storage
 The Super heater section is normally located in the hotter gas stream, in front of the evaporator.

Economizer :

 The Economizer Section, sometimes called a preheater or preheat coil, is used to preheat the feed
water being introduced to the system to replace the steam being removed from the system via the
super heater or steam outlet and the water loss through blow down.

 It is normally located in the colder gas downstream of the evaporator.

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 Since the evaporator inlet and outlet temperatures are both close to the saturation temperature for the
system pressure, the amount of the heat that may be removed from the flue gas is limited due to the
approach to the evaporator, whereas the economizer inlet temperature is low, allowing the flue gas
temperature to be taken lower.

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5. STEAM TURBINE

5.1 Introduction :

 A steam turbine is a mechanical device whose purpose is to convert thermal energy into work.

 Thermal energy is the type of energy that manifests itself as an increase in temperature.

 The steam turbine uses thermal energy from steam under pressure and converts it into rotary motion
or mechanical work.

 The original version of the steam turbine was the steam engine, which was powered by reciprocating
pistons.

 Steam turbines are idle prime movers for driving machines requiring rotational mechanical input
power.

 They can deliver constant or variable speed and are capable of close speed control.

 Drive applications include centrifugal pumps, compressors, ship propellers and electric generators.

5.2 Components of Steam Turbine :

 The main components of Steam turbines are

1. Casings
2. Blading
3. Blade carriers with stationery blades
4. Welded disc rotor with rotating blades
5. Dummy Piston
6. Rotor Coupling
7. Gland seals

Casings :

 Turbine casings are pressure vessels which contain the steam so that it can perform work by causing
rotation of the turbine shaft.

 The type and size of casing materials are determined primarily by pressure and temperature
conditions of steam.

 Components mounted in the casing are the blade carriers, turbine shaft and shaft seals. Blade carriers
hold and maintain the stationary blades in place.
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 The turbine shaft and rotating blades provide the torque to rotate the generator shaft.

 The mechanical energy conversion takes place across the stationary and rotating blades. Shaft seals
provide sealing between the casing and shaft.

 They prevent HP steam from leaking out and air from entering into the LP turbine, which is under
vacuum.

Blading :
 Turbine blades convert the thermal energy into mechanical energy, which is then supplied to the
generator via the rotor.

 Each stage consists of stationary and rotating blades. There are basically two types of blade designs
in use today.

1. Impulse design
2. Reaction design

 In the impulse design, theoretically all the pressure drop is across the stationary blading and
essentially none across the rotating blades.

 This design is characterized by a long, slender rotor with diaphragms, which are used for sealing.

 In the reaction design, there is an equal pressure drop across both the stationary and rotating blades,
which leads to very similar blade profiles.

 The reaction design is characterized by a drum type rotor.

 Since there is a pressure drop across the rotating blades, a thrust is developed which must be
compensated either by a dummy or balance piston or a modified steam path layout.

Dummy or Balance Piston :

 The design of reaction blading results in a pressure drop across both stationary and rotating blades.

 This means that a thrust force is applied to the rotor in the direction of steam flow.

 The most common method to reduce this force is to alternate the flow direction in the different stages
(HP, IP, LP) and to use a dummy or balance piston.

 The diameter of this piston is calculated as to minimize the force. This force varies with the different
operation data (MW output).

 It is transmitted via the axial bearing to the casing, and from there to the foundation.

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Rotor flange coupling :

 Couplings are introduced to increase the ability for individual overhaul and transport.

 Coupling flanges have honed bores into which coupling bolts with expansion sleeves are screwed.

 During operation, torque is transmitted by the shearing force of the bolts and sleeves.

 At the same time, the radially pre-tensioned sleeves center the coupling halves so they do not slip,
even in cases of electrical disturbances with high transient loads.

 The gas turbine and the generator are one unit and are coupled rigidly with an expansion sleeve
coupling.

 The steam turbine is used only in combination with combined cycle and therefore the coupling is
flexible.

 The design is made in such a way that the steam turbine can be started individually and will be
coupled to the generator at nominal speed.

Gland Seals :

 Stationary and rotating turbine components must be sealed to prevent steam leakages into the
atmosphere, air leakages into the LP turbine, maintain the correct and efficient steam flow within the
turbine.

 Since contact-type shaft sealing can cause distortion and deformation of the rotor, sealing segments
are designed to be non-contacting during operation thus limiting friction effects.

 The seal is built as a labyrinth for the steam which, passing the labyrinth, continuously loses
pressure.

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CONCLUSION
 Conclusion in review this internship has been an excellent and rewarding experience.

 I have been able to meet and network with so many people that I am sure will be able to help me with
opportunities in the future.

 One main thing that I have learned through this internship is time management skills as well as self-
motivation.

 When I first started I did not think that I was going to be able to make myself sit in an office for eight
hours a day, five days a week.

 Once I realized what I had to do I organized my day and work so that I was not overlapping or
wasting my hours.

 I learned that I needed to be organized and have questions ready for when it was the correct time to
get feedback.

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