SUMMER TRAINING

Training Report On POWER

GENERATION(DCCPP)
RAJ.RAJYA VIDYUT UTPADAN NIGAM LTD.

From- June15, 2011 to 14 July, 2011

Genration : 330 MW
Genrating Voltage : 10.5 KV
TRANS. VOLTAGE : 220 KV

SUBMITTED TO:- SUBMITTED BY:

Mr. Vinesh Agarwal Shobit Jain
H.O.D. (Electrical Engineering) B.Tech. Eletrical 7 th Sem

Department of Electrical Engineering

Institute of Technology & Management, Bhilwara

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 ACKNOWLEDGEMENT

I would like to express my gratitude to all those who gave me the possibilities
to complete this Industrial Training.

I want to thank the RAJ.RAJYA VIDYUT UTPADAN NIGAM LTD. for giving me
permission to commence this industrial training, in the first instance, to do
training on “COMBINED CYCLE POWER PLANT”.

I have furthermore to thank Mr. K.K. Chaturvedi last but not the least all
members of RAJ. RAJYA VIDYUT UTPADAN NIGAM LTD. for respective
stimulating support.

I am deeply indebted to my mentor Ms. UPMA GARG whose help, stimulating

suggestions & encouragement helped me in all the time during my industrial
training.

Last but not least I would like to thank the management of IET Group of
Institution & Mr.RAKESH SHARMA, HOD of E&C Dept. & all the faculty
members.

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 PREFACE

Practical training for a period of 30 days in a part of the B.Tech. after

fourth term in Electrical Engineering according to the syllabus
worked out by Rajasthan Technical University, KOTA (RTU) to which
my department is affiliated . I took a 30 working days at Raj. Rajya
Vidyut Utpadan Nigam Ltd. from 15/06/2011 to 14/07/2011.

The report is a summary of what I observed and learnt there. My

humble thanks are going to all the officer related of my training. I
also feel that it is right time to thank the officers and technicians of
the Shree Power Plant for the guidance, co-operation and the
knowledge extended by them time to time.

Shobit Jain
B.Tech Final Year(EE)

Roll No. : 08EIMEE055

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TABLE OF CONTENTS

1. GENERAL DESCRIPTION
11

2. GAS TURBINE
12-14

2.1 INTRODUCTION

2.2 THEORY OF OPERATION

2.3 ADVANTAGES OF GAS TURBINE

2.4 DISADVANTAGES OF GAS TURBINE

3. STEAM TURBINE
15-17
3.1 INTRODUCTION

3.2 PRINCIPLE OF WORKING OF STEAM TURBINE

4. CONDENSING PLANT 18-

21
4.1 INTRODUCTION

4.2 CIRCULATING WATER SYSTEM

4.3 CONDENSER

4.4 CONDENSATE SYSTEM

4.5 EVACUATION SYSTEM

4.6 SHAFT SEAL STEAM SYSTEM

4.7 PROCESS ENGINEERING FUNCTIONS OF CONDENSER

4.8 COMPONENTS OF THE CONDENSER

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 4.9 VACUUM BREAKER

4.10 ISOLATION VALVE DOWNSTREAM OF THE VACUUM BREAKER

4.11 LEVEL MONITORING EQUIPMENT

4.12 INFORMATION FOR OPERATION & MAINTENANCE

5. HP TURBINE
22-27
5.1 GENERAL ARRANGEMENT

5.2 STEAM FLOW

5.3 VALVE ACTUATION

5.4 DOUBLE SHELL CONSTRUCTION

5.5 ADMISSION PIPE UNITS

5.6 ATTACHEMENT OF THE INNER CASING

5.7 HP TURBINE CASING SUPPORTS AND GUIDE

5.8 HP TURBINE BLADING

6. LP TURBINE
28-31
6.1 CONSTRUCTION

6.2 BLADING,DRUM STAGES

6.3 STATIONARY AND MOVING BLADES

7.HP AND LP BYPASS(EHA TYPE)

32-33
7.1 FUNCTION

7.2 MODE OF OPERATION

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8. TURBO GENERATOR
34-37
8.1 WORKING OF TURBO GENERATOR

8.2 COMPONENTS OF GENERATOR

8.3 STATOR CORE

8.4 STATOR WINDING

8.5 STATOR FRAME

8.6 ROTOR

TABLE OF FIGURES

S.No. FIGURE NAME PAGE NO.

1. COMBINED CYCLE 9
2. GAS TURBINE 12
3. OPERATION OF GAS TURBINE 13
4. WORKING OF STEAM TURBINE 16
5. Ts DIAGRAM 17
6. HP TURBINE 23
7. ADMISSION PIPE UNIT 24
8. HP TURBINE CASING SUPPORT AND GUIDE 26
9. HP TURBINE BLADING 27
10. LP TURBINE 28
11. BLADING AND DRUM STAGES 30
12. STATIONARY AND MOVING BLADES 31
13. TURBO GENERATOR 35
14. GENERATOR CAPACITY vs WATER TEMP. CURVE 37
15. GENERATOR CAPABILITY CURVE 37

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INTRODUCTION

 Company’s profile
Rajasthan Rajya Vidyut Utpadan Nigam Limited (RVUN) has been entrusted
with the job of development of power projects under state sector, in the state
along with operation & maintenance of state owned power stations.
Government of Rajasthan constituted the Rajasthan Rajya Vidyut Utpadan
Nigam Ltd. (RVUN) under Companies Act-1956 on 19th July, 2000. The Nigam
is since playing lead role in giving highest priority to the power generation for
manifold and rapid development of the state.

The generating Stations of RVUN have acquired a distinctive reputation in the

country for their efficient and economic power generation. RVUN has track
record of completing the generation projects ahead of schedules.

 The present installed capacity of RRVUNL is 4097.35 MW...

 History of power development

The history of power developemnt in Rajasthan goes back to the year
1949,when 19 princely states merged to form Rajasthan.At that time,electric
power,was confined to very few towns,and electricity was considered a
luxury.The total number of towns and villages electrified at that time,did not
exceed 42 and the installed gererating capacity was only 13.27
MW.However,with the formation of Rajasthan State Electricity Board on 1st
july 1957,power sector in Rajasthan received priority and power projects
began to mushroom all over State.
Under new Power Reforms Undertaken by State Govt. RESB was unbundled
into following five Govt. Companies in July 2000.

Present capacity of Dholpur combined cycle power plant (CCPP) is 330MW…

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Intoduction of gas turbine power plant
In Gas turbines the turbines operate like a jet engine,

drawing in air,

compressing it,

mixing it with fuel,

and igniting it.

The hot combustion gases then expand through turbine blades connected to a
generator to produce electricity.

Advantages of gas turbine power plant

High thermal efficiency(in combined cycle)

Low water requirements

Environment friendliness

Fast start up

Low gestation period

Disadvantages of gas turbine power plant

Lower efficiency in open cycle

Higher cost of generation

Higher maintenance cost

The functions of gas power plant basically depends upon four types of cycle.

 Carnot
 Rankine
 Brayton
 Combined

But combined cycles have many advantages over these cycle.first let us see
what’s the combined cycle…
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Combined cycle
Combined cycle plants have both, a gas turbine fired by natural gas & a steam
boiler and steam turbine which use the exhaust gas from the gas turbine to
produce electricity.

Combined cycle is mostly use rather than other such as individually(gas

turbine, steam turbine)because it has high heat addition and very low heat
sinking property comparatively others.thats why it is highly efficient,better
performance …

Fig .1 combined cycle.

Combined cycle power plant(CCPP) have many advantages such as high

efficiency,low cooling water requirement,fast start,loe environment pollution,

low costs etc…

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basic blocks of combined cycle
 Compressors
 Combustion chambers
 Gas turbine
 Steam turbine
 Generators

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Chapter-1

GENERAL DESCRIPTION
The turbine control system description comprises the following description
modules:

General description

Start up procedure

Speed control

Remote speed indication

Protective devices

Over speed trip test

Testing of stop valves

HP and LP bypass control system

The combined cycle plant comprises to gas turbine generators each with a
dedicated dual pressure heat recovery steam generators(HRSG) sharing a
common steam turbine generator. A dedicated main system by pass control
and a dedicated induction steam by pass control are provided for each steam
generator. This permits operation of a single gas turbine generator in a
conduction with a single HRSG.

Turbine generator unit comprises of HP turbine MAA50 HA001 and LP turbine

MAC10 HA001 with condenser MAG10 AC001 and a direct drive 3 phase AC
generator.

The first cylinder is supplied with steam from the heat recovery steam
generator via two combined main steam stop and control valves…

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Chapter -2

GAS TURBINE
2.1 Introduction
This machine has a single-stage centrifugal compressor and turbine, a
recuperator, and foil bearings.

A gas turbine extracts energy from a flow of hot gas produced by combustion
of gas or fuel oil in a stream of compressed air. It has an upstream air
compressor (radial or axial flow) mechanically coupled to a downstream
turbine and a combustion chamber in between. Gas turbine may also refer to
just the turbine element.

Fig .2 Gas turbine.

2.2 Theory of operation

Gas turbines are described thermodynamically by the Brayton cycle, in which
air is compressed isentropically, combustion occurs at constant pressure, and
expansion over the turbine occurs isentropically back to the starting pressure.

In practice, friction, and turbulence cause:

a) non-isentropic compression: for a given overall pressure ratio, the

compressor delivery temperature is higher than ideal.

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b) non-isentropic expansion: although the turbine temperature drop necessary
to drive the compressor is unaffected, the associated pressure ratio is greater,
which decreases the expansion available to provide useful work.

c) pressure losses in the air intake, combustor and exhaust: reduces the
expansion available to provide useful work.

Fig .3 Operation of gas turbine.

As with all cyclic heat engines, higher combustion temperature means greater
efficiency. The limiting factor is the ability of the steel, nickel, ceramic, or other
materials that make up the engine to withstand heat and pressure.
Considerable engineering goes into keeping the turbine parts cool. Most
turbines also try to recover exhaust heat, which otherwise is wasted energy.
Recuperators are heat exchangers that pass exhaust heat to the compressed
air, prior to combustion. Combined cycle designs pass waste heat to steam
turbine systems. And combined heat and power (cogeneration) uses waste
heat for hot water production.

Mechanically, gas turbines can be considerably less complex than internal

combustion piston engines. Simple turbines might have one moving part: the
shaft/compressor/turbine/alternative-rotor assembly (see image above), not
counting the fuel system.

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More sophisticated turbines (such as those found in modern jet engines) may
have multiple shafts (spools), hundreds of turbine blades, movable stator
blades, and a vast system of complex piping, combustors and heat exchangers.

As a general rule, the smaller the engine the higher the rotation rate of the
shaft(s) needs to be to maintain tip speed. Turbine blade tip speed determines
the maximum pressure that can be gained, independent of the size of the
engine. Jet engines operate around 10,000 rpm and micro turbines around
100,000 rpm.

Thrust bearings and journal bearings are a critical part of design. Traditionally,
they have been hydrodynamic oil bearings, or oil-cooled ball bearings. This is
giving way to foil bearings, which have been successfully used in micro turbines
and auxiliary power units.

2.3 Advantages of Gas Turbine

•Very high power-to-weight ratio, compared to reciprocating engines (ie. most
road vehicle engines);

•Smaller than most reciprocating engines of the same power rating

•Moves in one direction only, and doesn't vibrate, so very reliable;

•Simpler design.

2.4 Disadvantages of Gas Turbine

•Cost is much greater than for a similar-sized reciprocating engine (very high-
performance, strong, heat-resistant materials needed);

•Use more fuel when idling compared to reciprocating engines - not so good
unless in continual operation.

These disadvantages explain why road vehicles, which are smaller, cheaper and
follow a less regular pattern of use than tanks, helicopters, large boats and so
on, do not use gas turbine engines, regardless of the size and power
advantages imminently available.

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Chapter-3

STEAM TURBINE
3.1 Introduction
It has completely replaced the reciprocating piston steam engine invented by
Thomas Newcomen and greatly improved by James Watt primarily because of
its greater thermal efficiency and higher power to weight ratio. Also, because
the turbine generates rotary motion, it is particularly suited to be used to drive
an electrical generator--it doesn't require a linkage mechanism to convert
reciprocating to rotary motion. The steam turbine is a form of heat engine that
derives much of its improvement in thermodynamic efficiency to the use of
multiple stages in the expansion of the steam (as opposed to the one stage in
the Watt engine), which results in a closer approach to the ideal reversible
process.

A steam turbine extracts the energy of pressurized superheated steam as

mechanical movement.

3.2 Principle of working of steam turbine

A steam turbine is a prime mover that derives its energy of rotation due to
conversion of the heat energy of steam into kinetic energy as it expands
through a series of nozzles mounted on the casing or the fixed blades.”

Water is converted to steam by application of heat in the boiler, which makes

the steam at specified pressure and temperature. To convert the steam’s
energy into work, it must go through a thermodynamic cycle that combines
expansion compression, heat input, and heat rejection. The most efficient
thermodynamic cycle for an ideal fluid is Carnot cycle. It consists of an
isothermal heat input, isentropic expansion, isothermal heat rejection, and an
isentropic compression. Regardless of the combination, the efficiency of the
cycle, assuming constant mass flow is based on the difference in the enthalpy
and between the beginning and end of the cycle.

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 Fig .4 Working of steam turbine.
Steam can be used as the working fluid in the Carnot Cycle. But its properties
adversely impact its usefulness. In this case the steam expansion process takes
place completely in the moisture region. This requires compression of a
vapour/moisture mixture to return to the cycle’s starting point. Moisture is an
expansion process imposes large mechanical efficiency losses. Also, vapour
compression is inefficient and consumes relatively large amounts of power.

To avoid a two-phase vapour compression process, turbines are based on the

Rankine cycle. It is similar to the Carnot Cycle, except that the initial pressure
of the steam is raised and the condensation process that accompanies heat
rejection continues until the liquid saturation point is reached. At the end of
the cycle, then, condensate is simply pumped back to the boiler to begin the
cycle. The role of the steam turbine is to expand the steam from high pressure
and temperature to lower pressure and temperature.

Rankine cycle is a heat engine with vapor power cycle. The common working
fluid is water. The cycle consists of four processes:

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 Fig .5 Ts diagram.

1 to 2: Isentropic expansion(Steam turbine)

2 to 3: Isobaric heat rejection(Condenser)

3 to 4: Isentropiccompression (Pump)

4 to 1: Isobaric heat supply(Boiler)

Several things can be done to steam to improve the Rankine Cycle efficiency.
Raise initial steam condition and reduce the amount of moisture near the end
of expansion stage. The first is accomplished by superheating the steam before
it does any work. The second involves re- heating steam to near initial-
conditions after it is partially expanded by directing it back to the heat source,
then completing the expansion.

In converting the thermal energy of steam into mechanical energy turbines

takes advantage of this facts- as it expands or drops in pressure, through a
small nozzle or opening, it accelerates and forms high-speed jet. Directing this
momentum in a rotating blade provides mechanical energy.

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Chapter-4

CONDENSING PLANT
4.1 Introduction
The condensing forms the main heat sink of the power plant unit. The
following systems are involved in the process engineering function:

Circulating Water System PA

Condenser MAG

Condensate System LCA & LCB

Evacuation System MAJ

Shaft Seal system MAW

4.2 Circulating Water System

The circulating water system, whose essential components are the circulating
water pumps and pipings, has the function of supplying the condenser with
circulating water for removing the heat of the vaporization of the condensed
steam.

The circulating for condenser must meet certain requirements i.e. it must be
free of solid contaminants, which can be deposited in or in front of condenser
tubes.The strainer system & dosing equipment aid in maintaining circulating
water requirements and also form part of the circulating water system.

4.3 Condenser
The steam expanded to condenser pressure in the steam turbine and / or
bypass valve condenses in the condenser by removing the heat of the
evaporation.

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4.4 Condensate System
The condensate accumulating in the condenser is fed back into water-steam
circuit by the condensate system pumps. The level controller has the function
of maintaining constant level in the condenser. The control valves of the
condenser level controller forms the part of the condensate system. The
condensate system also provides:

Injection water for bypass steam.

Injection water for the flash tanks of the

condenser.

Seal water for glands of the valves

operating under vacuum.

Cooling water for seal steam condenser.

4.5 Evacuation System

The vacuum pumps of the evacuation system remove air & other non
condensable gases from the condenser during startup and operation.

4.6 Shaft Seal Steam System

The shaft seal steam system supplies seal steam to the shaft seals of LP
Turbine, through which air can ingress into the condenser due to negative
internal pressure. The seal steam is either supplied directly or in the form of
leakoff steam from the shaft seals of the other turbines.

4.7 Process engineering functions of condenser

The surface condenser has function of condensing steam expanded in the
turbine and /or in the bypass valves.The steam or condensate from shaft seal
system and the leakoff steam system are fed into the condenser.Condensate
collecting in the hot-well of the condenser is drawn off by the condensate
pumps and returned to water-steam cycle.

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4.8 Components of the condenser
The condenser has following components:

Vacuum Breaker MAG10AA001.

Isolation valve downstream of vacuum breaker MAG10AA501.

Level monitoring equipment with ID code in accordance with system diagram.

4.9 Vacuum Breaker

During turbine operation boundary conditions can arise under which the
turbine generator coast down time during shut down should be as short

as possible. On opening the vacuum breaker, air is admitted into the

condenser, thereby increasing the condenser pressure. The windage in the
blading slows down the speed of the rotor system and reduces the coasting
down time. The vacuum breaker opens automatically when the turbine fire
protection is activated. Other criteria for opening of the vacuum breaker are:

The limit value of one of the following parameters is reached:

- Shaft or bearing vibration.

- Bearing temperature.

- Casing distortion due to temperature differences between top & bottom

halves of the casing.

- Shaft position in the thrust bearing.

Vibration increases drastically when passing through critical speeds during

coasting down of rotor system.

Air must not be drawn over the seat of the vacuum breaker. Hence, the seal
water valve for the vacuum breaker must always be open so that some seal
water flows out of the overflow line.

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4.10 Isolation valve downstream of the vacuum breaker
The isolation valve downstream of the vacuum breaker must be open during
normal operation and should only be closed when the vacuum breaker opens
spuriously.

4.11 Level Monitoring Equipment

The level monitoring equipment has the following functions:

Output of a control signal for the condenser level controller, which is part

of the condensate system.

Signaling an inadequate condenser level, which cause the condensate

pumps to malfunction.

Signaling an excessive condenser level.

4.12 Information for operation & maintenance

Technical Data:

The technical data contains the limit pressure setpoints of the condenser
protection system.

Overpressure Protection Of Condenser:

The rupture discs of the LP turbine protect the condenser against excessive
internal pressure.

Condenser Protection System:

Condenser Protection System protects the condenser & turbine against

operation at inadmissible condenser pressure.

Condenser Protection Against Excessive Steam Temperature Superheated

steam, which is fed into the condenser through lance pipes, must be cooled in
the flash tanks.

Isolation valves in the condensate lines to the flash tanks must be opened.

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Chapter-5

HP TURBINE
5.1 General Arrangement
The HP turbine has two stop valves and two control valves located on each side
of the turbine casing. The valves are arranged in pairs with one main stop valve
and one control valve in a common body (1).

5.2 Steam Flow

The main steam is admitted through the main steam pipes (2) and passes first
the main stop valves and then the control valves. From the control valves the
steam enters the turbine casing (3). The shortlength of the admission pipes (4)
between the control valves and the casing results in a very low steam volume
in this section, which gives the turbine excellent trip reliability. For easy
maintainability, the steam inlet connection to casing top half is made through a
flanged joint (7).

5.3 Valve Actuation

Each main stop valve and control valve has a dedicated hydraulic servomotor
(5,6). The servomotors are mounted above floor level so that they are easily
accessible for operation and maintenance.

5.4 Double Shell Construction

The casing of the HP turbine is split horizontally and is of double-shell
construction. A single-flow inner casing (3) is supported in the outer casing (2).
The initial steam enters the inner casing from above and below through two
admission branches.

The provision of an inner casing confines the high- temperature and high-
pressure steam inlet conditions to the admission section of this casing, while
the outer casing is subjected only to the lower pressure and temperature
effective at the exhaust from the inner casing.

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This means that the joint flange of outer casing can be kept small and material
concentrations in the area of the flange reduced to a minimum, thus avoiding
difficulties arising from deformation of a casing with flange joint due to non-
uniform temperature rises, e.g,. on startup and shutdown. The joints of the
inner casing are relieved by the pressure in the outer casing so that these joints
only have to be sealed against the resulting differential pressure.

Fig .6 HP Turbine.

5.5 Admission Pipe Units

The Angle-ring (7) form the connection of the admission pipe units to the inner
casing (3) (Detail D). One leg of the Angle-ring (7) at such a connection engages
behind the collar of the threaded ring (5) in the admission pipe unit, while the
other fits into an annular groove in the inner easing. The threaded ring (5) is
fitted in such a way that the short leg of the Angle-ring can slide freely
between the collar of the threaded ring and the admission pipe unit.

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The steam pressure prevailing on the side forces the seal ring against the face
of the admission pipe unit. The tolerances of the annular groove in the inner
easing are dimensioned to allow the long leg of the Angle-ring (7) to slide. The
Angle-ring is flexibly expanded by the pressure on the inside and its outer
areas are forced against the annular grooves to provide the desired sealing
effect.

While providing a tight seal, this arrangement permits the inner easing to
move freely in all directions.

The admission pipe units are welded to the outer casing.

Fig .7 Admission Pipe Unit.

5.6 Attachment of the Inner Casing

Due to the different temperatures of the inner casing relative to the outer
casing, the inner casing is attached to the outer casing in such a manner as to
be free to expand axially from a fixed point and radially in all directions, while
maintaining the concentricity of the inner casing relative to the rotor.

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The steam admission connections are designed to avoid constraining thermal
expansion in any way. The inner casing is attached to the outer casing in the
horizontal and vertical plane.

5.7 HP turbine casing supports and guide

The turbine casing is supported in such a way so as to make allowance for
thermal expansion. It is essential for the casing to retain concentric alignment
with the rotor, which is supported independently. The turbine casing (2) is
supported by its two front and two rear palms on the palm supports of the
bearing pedestals (1,3) at the turbine center line level. This arrangement
determines the height of the casing and also allows thermal expansion to take
place in the horizontal plane by the casing palms sliding on the sliding pieces
(6) mounted on the bearing pedestals (1,3). To prevent lifting of the turbine
casing (2) the palms projecting into the corresponding recesses in the bearing
pedestals are held by the clamping plate (4). When the turbine is erected, a
clearance "s" is allowed between the palm projection of turbine casing (2) and
the clamping plate (4) through screwed thrust bar (5), thus restricting the
casing lift. In addition, the HP turbine casing support on front bearing pedestal
joins the casing and the pedestal into a single unit in axial direction by means
of sliding pieces (7). No such anchoring is there in casing rear, supported on

the LP front bearing pedestal. This means that the axial expansion of HP
turbine initiates from front bearing pedestal (1) and is transmitted towards LP
front pedestal (3).

Guides The transverse location of the turbine casing at right angles to the
machine axis is provided by the guides shown in Detail-B.These guides allow
the turbine casing to expand freelly in vertical as well in axial direction, and
restrict movement in transverse direction through sliding pieecs (8) and
parallel keys (9).

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 Fig .8 HP Turbine casing supports and guide.

1)HP front bearing and pedestal

2)HP turbine and casing

3)LP front bearing and pedestal

5.8 HP turbine blading

Moving and Stationary Blades:

The HP turbine blading consists of 28 drum stages. All stages are reaction
stages with 50% reaction. The stationary and moving blades of allstages (Fig. 1)
are provided with inverted T-roots and integral shrouds.The moving and
stationary blades are inserted into corresponding grooves in the shaft (1) and
inner casing (2) and are caulked at bottom with caulkirig material (5). The
insertion slot in the shaft is closed by a locking blade which is fixed by taper
pins or grub screws. Special end-blades which are locked with the joint plane
by grub screws are used for the, inner casing.

Gap Scaling:

Sealing strips (6) are cawked into the inner casing (2) and the shaft (1) to
reduce leakage losses at the blade tips. Cylindrically machined surfaces on the
blade shrouds are opposite the sealing strips.
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The surfaces have stepped diameters in order to increase the turbulence of the
steam and this the sealing effect. Should an operational disturbance. cause the
sealing strips to come into contact with opposite surfaces, they are rubbed
away without any considerable amount of heat being generated. They can
then easily be replaced at a later date to provide the specified clearance.

Fig .9 HP Turbine Blading.

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Chapter-6

LP TURBINE
6.1 Construction
The LP turbine casing consists of a double flow unit and has a triple shell
welded casing. The outer casing consists of the front and rear walls, the two
lateral longitudinal support beams and the upper part. The front and rear walls
as well as the connection areas of the upper part are reinforced by means of
circular box beams. The outer casing is supported by the ends of the
longitudinal beams on the base plates of the foundation.

1)outer casing,upper half 3)inner shall,upperhalf 6)diffuser

2)outer shell,upper half 4)inner shall,lower half 7)outcasing,low half

Fig .10 LP Turbine.

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6.2 Blading ,Drum stages
Arrangement:

The drum blading stages of the double flow L.P. turbine are reaction stages
with 50% reaction. They are Located in the inlet region and thus form the front
part of the blading. The LP stages following this blading are described in detail
in a separate section [1].

Stationary and moving blades:

All stationary and moving blades are provided with integral shrouds which
after installation form a continuous shrouding. All stationary and moving
blades have t-roots which also determine the distance between the blades.
They are inserted in mating grooves in shaft (6) and inner casing (1) and are
caulked in place with caulking material (5). The Insertion slot in the shaft is
sealed by means of a locking blade which is held in position by grub screw. The
stationary blades are held in position in the grooves of grub screw that are
screwed into the inner casing material and the blades lock from the joint
surface.

Gap Sealing:

In order to reduce blade tip losses, seal strips (7) are caulked into the inner
casing (1) and turbine shaft (6). The seal strips are located opposite integrally
machined seal-points on the blade shroud (Detail A). This design gives
favourable radial clearance. In the event of rubbing due to a fault, the seal
strips are worn away without generating much heat. They can then be easily
replaced at a later date to restore the required clearances.

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 Fig .11 Blading and Drum Stages.

6.3 Stationary and moving blades

The last three stages of the LP turbine are designed as reaction stages. Each
stage is made up of stationary and moving blades. The stationary blade rings
are made by welding inner rings, blades and outer rings together into
segments and bolting them to inner casing (5). The two final stages have
blades which are made of sheet steel and are hollow. Drainage slots are
provided in the blade (6) of these rows. Through these slots any water
impacting on these blades is drawn away to the condenser. When the
stationary blade rings are installed in place, inner rings attached to these form
a continuous ring of shrouding. The moving blades (3) have T-roots which are
inserted into corresponding grooves in the turbine shaft and caulked with
caulking material (2). The moving blades (7) inserted in axial grooves in the
turbine shaft (1) have curved fir-tree roots (see view B). These are attached
with filler pieces (11) and secured against axial movement of the blades by
retaining strips (10), the end segment of which are welded together at the
joint. The difference in circumferential speed at the root and tip of the moving
blades is taken into consideration by the twisted design of the blades.

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 Fig .12 Stationary and Moving Blades.

1)turbine shaft

2)caulking material

3)moving blades

4)stationary blade rings

5)inner casing

6) stationary blade rings

7) moving blades

8) caulking material

9)seal strip

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Chapter-7

HP AND LP BYPASS(EHA TYPE)

7.1 Function
The function of the bypass control system within the combined cycle is to
dump steam to the condenser via HP and LP bypass stations in the event of
transient turbine operating conditions such as turbine trip, load rejection,
start-up and shutdown.

7.2 Mode of operation

Each of the two-dual pressure steam generators (HP and LP) is provided with a
dedicated bypass control of essentially identical design. Each stop valve (SV)
and control valve (CV) of HP and LP bypass system is provided with its own
Electro-Hydraulic Actuator (EHA).The EHA for each SV consists of an operating
cylinder with control piston and disc springs and a control unit flanged to the
operating cylinder and limit switches to monitor the opening and closing of the
actuator. The control unit comprises of the Pilot Valve (solenoid operated), 2
nos. Trip Solenoid Valves (TSV) and 2nos. cartridge valves. The actuator (EHA)
of CV consists of operating cylinder with control piston (with out disc springs)
and a valve position transmitter for measuring the position of the valve. The
control unit flanged to the operating cylinder, comprises of the Servovalve, an
interlocking valve and 2 nos. pilot operated check valves. The interlocking and
check valves ensure that the CV remains in stay-put position on failure of the
oil supply. The EHA of the bypass valves is supplied with high pressure control
oil (160 bar) from centralized HPSU (Hydraulic Power Supply Unit). A sequential
control logic (SGCHPSU) controls the startup and shutdown of the HPSU. The
function of the bypass controllers is to maintain pressure in the steam
generator at a load dependent setpoint by operating the bypass valves. During
turbine startup andshutdown, the steam not accepted by the HP/LP turbine is
dumped into the condenser by HP/LP bypass valves with water being injected
into the bypass steam downstream of the bypass valves to attemperate it.

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Each bypass controller consists of a pressure controller and a position
controller. The opening and closing of the bypass SV is done over a pilot valve
(solenoid operated) which is controlled in relationship with the pressure
controller output signal. The pressure controller output also acts as a setpoint
for the subordinate position controller. The position controller output acts on
the servo-valve to open or close the bypass control valve. The analog position
of the CV is fed back to the position controller by an analog position
transmitter. HP and LP bypass control system includes the necessary protective
devices for the condenser and interlocks for the water injection system. These
are as follows:

Fast closure (tripping) of the bypass valves is required in response to any of the

following:

-Condenser vacuum too low

-Water injection pressure too low

-HPSU emergency OFF

-HPSU:- Control oil pumps protection OFF (generated from pump discharge oil
pressure)

- Manual initiation of bypass trip from Emergency OFF PB in the control room.

Quick closure of the SV is effected through the TSVs. Closing of the CV is done
through the Servo-valve, with signal going to the pressure controller from the
Bypass Trip System.

Note:- This is a general description of HP and LP Bypass system (EHA Type). HP

and LP Bypass system (EHA Type) is supplied by M/S Bomafa Armaturen
GMBH, Germany and O & M manual supplied by vendor may please be
referred for detail description.

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Chapter-8

TURBO GENERATOR
An Turbo generator is an electromechanical device that converts mechanical
energy to electrical energy, using a rotating magnetic field.

8.1 Working of turbo generator

An Turbogenerator generally includes a rotor that rotates within a stator core
to convert mechanical energy into electrical energy.

A frame-supported stator core provides a high permeability path for magnetic

flux and a rotor assembly positioned to rotate continuously within the stator
core so as to induce electrical current.The resulting current is carried by high-
current conductors through and out from the power generator, to connectors
that provide the current to a plant bus for power distribution.

8.2 Components of generator

Stator-Stator Frame (Fabrication & Machining)

Core Assembly-Stator Core, Core Suspension Arrangement

End Shield

Stator Winding Assembly-Stator Winding , Winding Assembly, Connecting Bus

bar, Terminal Bushing

Rotor-Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor, Rotor Assembly

Completing Assembly-Bearing Assembly, Shaft Seal Assembly, Oil Catchers,

Insert Cover etc

Exciter

Auxiliary Systems

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 Fig .13 Turbo Generator.

8.3 Stator core

 Made up of punched segments of thin sheets of ETS

 Punchings coated by insulating varnish

 Vent segments at designed intervals for flow of cooling gas

 Compressed with tension bolts, pressure plate and clamping fingers

 Stepped arrangement at the end for reduction in eddy current losses

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8.4 Stator winding
The Pre-insulated and pre-shaped bars are placed into the slots of the stator
core.The Insulated bars in the slot section are covered with pre-fabricated
glass fabric pads and locked by inserting slot wedges.

Specially treated taps are applied to the bar portion just outside the slot to
take care of corona discharges.

The micalastic post impregnation process insures a mechanically firm bond

between all winding components.

8.5 Stator frame

Rigid fabricated cylindrical frame

Withstands weight of Core & Winding, Forces & Torques during operation

Natural frequency away from exciting frequencies

8.6 Rotor
Retaining Ring Assembly:

For containing centrifugal forces of the rotor end windings.

Made of non-magnetic high-strength steel in order to reduce stray losses.

Shrunk onto the rotor body in an overhung position with its shrink fitted insert
ring.

Secured in the axial position by a snap ring.

Field connection:

For supplying field current to the rotor winding Through radial terminal
bolts(CC Bolts) and two semicircular conductors (D-leads) located in the hollow
bores of the exciter and rotor shafts. The field current leads are connected to
the exciter leads at the exciter coupling with Multikontakt plugin contact which
allow for unobstructed thermal expansion of the field current leads.

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 GENERATOR CAPACITY vs COOLING WATER TEMPERATURE

260

250

240

230

220 Series1

210

200

190

180
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Fig .14 Generator capacity vs Water Temp. Curve.

ACTIVE
POWER
TURBINE 0.85
OUTPU
LIMIT ROTOR
T
0.80 HEATIN
STABILITY G LIMIT
LIMIT
0.70

LEADIN LAGGIN
G MVAR G MVAR

Fig .15 Generator Capability Curve.

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 CONCLUSION
Hence we have analysed how to power generate and what are the basic
building blocks of the power generation project such as compressor,
combustion chambers, gas turbine, steam turbine and turbo generator…

How Power is supplied to the transmission line. We also observe construction

of gas turbine,steam turbine, turbo generator etc…

Power generation plants are very efficient, reliable, highly performance and
gives tremendous results.

Power generation plants are very economical.

There are 8 plants working under the RAJASTHAN RAJYA VIDYUT UTPADAN
NIGAM LTD.and present total installed capacity of rajasthan rajya vidyut
utpadan nigam ltd. Is 4097.35 MW… and the present installed capacity of

Dholpur Combined Cycle Power Plant is 330 MW…

Some other power station are:Suratgarh TPS,Kota TPS,Chhabra super thermal

power station,Ramgarh gas power plant,Mahi hydel,MMH schemes,Giral
lignite TPS...

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 REFERENCES

 Mannuals probided by CCPP Dholpur contains brief description about

the control system, maintenance,technical data,protective device,fault
tracing etc…

 www.rvunl.com

 www.rajpower.com

 some other sites like Wikipedia etc….

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