Captive Power Plant

Introduction
• HPL has a Combined Cycle Cogeneration Power Plant
primarily meant for uninterrupted supply of Steam
and Power to all Process Plants and Utilities.
• It is connected to WBSETCL grid through two 132 KV
incomers.
• It despatches power to HPL at 33KV through three
outgoing feeders
• It is connected to the steam network of the complex
at 4 levels (SHP, HP, MP and LP)
• It receives all fuel and utilities from the integrated
offsites and utilities plant of HPL. Storage facility is
available in CPP.
• It is certified as per ISO 9001,14001, OHSAS 18001.
Description
• Type of Plant : Combined Cycle Cogeneration Power Plant

• Installed Capacity : Power:116 MW

(GTG: 2X34.5, CSTG: 1X33, BPSTG: 1X14MW)
Steam: 524 TPH
(HRSG: 2X(120+22)TPH, Boiler: 2X120TPH)

• Fuels Used : 1. Naphtha ,

2. Carbon Black Feed Stock,
3. Residual Fuel Gas (RFG)
Equipment Details

1. 2 x 34.5 MW Gas Turbines

2. 1 x 33 MW Condensing Steam Turbine

3. 1 x 14 MW Back Pressure Steam Turbine

4. 2 x 142 TPH Heat Recovery Steam Generators

5. 2 x 120 TPH Service/Auxiliary Boilers

6. Other supporting systems

(also referred to as Balance Of Plant)

7. Electrical Systems
(a)132, 33, 6.6KV substations consisting of switchgears, MCCs and protection
systems
(b) Generators and transformers
Single Line Flow Diagram
MP Steam header
Fuel pumps.
34 MW

MPS CSTG

Air HRSG-1
120 TPH 33 MW
SHP
GTG 1
MPS

Air
HRSG-2 120 TPH BPSTG
SHP
GTG 2 14 MW
34 MW

AB-1 120 TPH

LP Steam
PRDS;3 no.s MP Steam
BFP: 2 no.
HP Steam

AB-2 120 TPH

BFW
SHP Steam header

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Gas Turbines (GT1 and GT2)
Technical Data
1. Capacity:- 34.5 MW ISO rating (at 15C,60%RH,sea
level)
2. Fuel : Naphtha/HSD/RFG
3. Make/ model: GE PG 6551B/ 6581B
4. Control system:
Mark V TMR (GT-1)/ Mark VIe (GT-2).
5. Combustors: Standard non-DLN type dual fuel.

Note:
1. GT -2 was modified in 2010 to use RFG in
combination with naphtha and some turbine parts
replaced with uprated parts.
2. GT-1 and GT-2 were uprated in 2017-18 for
achieving higher output and lower heat rate by
replacing turbine components with improved
sealing and aero dynamic profile.
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Heat Recovery Steam Generators (HRSG 1 and 2)

1. There are two HRSGs, each connected with one gas turbine.
The HRSGs generate steam at two levels SHP and MP using
the gas turbine exhaust gases.
2. There are six supplementary duct burners capable of firing
naphtha & RFG.
3. Each HRSG has got 5 vertical modules having 29 tube panels
each comprising of SHP and MP superheaters, evaporators
and economisers.
4. Capacity: 120TPH SHP and 22TPH MP steam
5. Make: L&T

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Auxiliary boilers (AB 1 and 2)
Technical Data

1. Capacity: 120 TPH

2. Generates SHP steam at 130bar/ 540C.
3. Fuel : Naphtha, CBFS & RFG
4. Burner: 4 nos wall burners
5. Fans: 2*100% FD fans(1*MD + 1*TD)
6. Make: Mitsui Babcock

The boiler is single drum, forced draft, top supported, radiant

furnace, natural circulation type

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Condensing Steam Turbine Generator
Make/ model: ABB Nurenberg/ C-160
Inlet steam: 130bar/ 540C.
Capacity: 33MW. Rated speed: 7059/min
No of Stages: 1 control, 17 reaction stages

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Back Pressure Type Steam Turbine Generator
Make/ model: ABB Nurenberg/ GE-32
Inlet steam: 130bar/ 540C (With HP bleed, MP extraction and LP exhaust).
Capacity: 14MW. Rated speed: 8297/min.
No of Stages: 2 control, 11 Reaction stages

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Balance of Plant (BOP) Equipments
• Induced draft cooling tower and CW circulation system.
• Fuel Storage and Pumping systems.
• Boiler Water Treatment Chemical Storage and dosing system.
• Cooling Water Treatment Chemical Storage and dosing system.
• De-aerator and BFW pumping systems etc.
• Pr. Reducing and De-superheating Station (SHP-HP, HP-MP, MP-LP)
• 132KV switchyard with 2X132/33KV, 50MVA grid transformers. CPP is
connected to WBSETCL grid through two 132 KV incomers.
• Emergency DG set (1500KVA, 6.6KV), for black start.
• Residual Fuel Gas compressor for compressing RFG before using in GT2.
• Un-interrupted power supply (UPS) for critical loads.
• 33 KV, 6.6 KV, 415V distribution system and its protection.
• Separate control systems for CSTG, BPSTG, GT-1, GT-2, BOP and Electrical
Control and Data Acquisition System (ECS)
This plant is having adequate safety measures for fast islanding from the grid
and automated load management system.

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Fuel Storage facilities
Fuel Dia (M) Height (M) Capacity (cu-M) Type
Naphtha 11.5 9 720 2 nos atmospheric, floating
roof
CBFS 9.1 8 400 1 no atmospheric, fixed roof,
insulated with steam heating
coil

HSD 5.0 6 118 1 no atmospheric, fixed roof

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Electrical System Overview

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Highlights of Energy Optimisation Project (EOP)
Implemented in 2010 at a total project cost of ~Rs.70 Crs
1. Following modifications were carried out in boilers for using CBFS as alternate fuel:
-Burner tips were changed.
-Soot blowing system was installed.
-New CBFS Fuel pumps were installed, existing CBFS tank was modified.

2. Following modifications were carried out in GT2 for using RFG as alternate fuel:
-Gas Turbine Fuel nozzles were replaced by dual fuel type.
-Two stage Screw compressor was installed for compressing fuel gas before using in
GT with necessary piping/ instrumentation.
-High pressure nitrogen compressor was installed for compressing nitrogen (buffer
and purge gas) with necessary piping/ instrumentation.
-Fuel Gas Module with gas filtration, gas control valves, stop ratio valves was installed
for regulating supply of required amount of fuel gas to combustor depending upon
load.
-Some turbine parts were replaced with uprated parts.
- Separate CO2 flooding system provided for Fuel Gas Module.
- Additional logics and protections were configured in the control system.
Gas Turbine : Cross Sectional View
Boiler Water Parameters
THANK YOU