Vocational Training Report for Combined

A STUDY REPORT ON COMBINED CYCLE POWER PLANT AT HAZIRA, SURAT

Submitted by: VIRAL J. PATEL

Department Of Mechanical Engineering. Govt. engineering valsad, Gujarat. college,

ACKNOWLEDGEMENT

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We find it most difficult part of the entire project to record our gratefulness to various persons to extended us more than the necessary quantum of co-operation & help in this project. The words that follow are merely the formal expression of are deep sense of indebtedness that is better treasured in thoughts that said in words. It is pleasure giving verbal expressions to our feeling of deepest gratitude towards Mr.Anil Matoo (Head HR dept.) , Mr.Nishith Dayal, SVP (Maintenance) & Mr. Sandip Sinha,VP (Purchase) and our project guide also who guided and encouraged us during the entire training period . We would also like to express our gratitude to Mr. Ramesh Reddi, Mr. Moreshwar Wanjari, Mr. Shailendra sah,, Mr. S.Boothalingam, Mr. Sandip Goel, Mr. Nilesh Varasada, Mr. Amlan De Sarkar,Mr. D. Patel of mechanical department also Mr. Gulshan Rana,HR Department for their unreserved co-operation, constant guidance and constructive criticism. We are very thankful to Essar Group for giving us this golden opportunity to complete our training from a renowned industry.

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CONTENT
1. 2. 3. 4. 5. 6. 7. About Essar Essar Combined Cycle power plant Simple and Combined Cycle Gas Turbine and auxiliaries Heat Recovery Steam Generation Steam turbine and auxiliaries Water Treatment Plant Soften Plant DM Plant

ESSAR POWER

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Powering Ahead
COMPANY OVERVIEW:
The Essar group is one of Indias largest corporate houses. Its interests span the manufacturing and service sectors in both the old and new economies; in steel, telecom, shipping, oil, power and construction. Its massive investments over the past decade have created compelling tangible and intangible assets that have now begun to release value.

ESSAR POWER:
substantially, giving us one of the lowest costs of production in India. The government has notified Essar Power as an infrastructure company, giving us the advantage of lower interest charges. Essar power is a significant force on Indias private power generating landscape. It set up Indias first new generation independent power plant at Hazira, Gujarat, after the government open the power generation to private participation in the early 1990s. It has consistently set new standards of excellence in the Indian power sector and meets the highest operating benchmarks. It supplies around 7% of the Gujarat states power needs. . Being India's first multi-fuel plant, it can operate simultaneously

on naphtha and gas, which will be a major advantage once LNG

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becomes freely available. By switching over to LNG, our variable costs have fallen Essar Power Limited has an immaculate track record of safety. The Company has been consistently winning safety awards from various institutions. This award has been conferred on Essar Power Limited for maintaining excellent record in safety and successfully maintaining the incident rate far lower than that of national standards of U.K. and also striving for the continuous improvement in Health and Safety standards. Earlier it had received this award in the year 1998 and 1999.

Key value drivers:

- 515MW plant, which is Indias first independent power plant and first multi fuel plant. World-class plant design and construction, equipment from General

Electric, Siemens and Honeywell. Highly automated, with Indias lowest manpower to megawatt ratio. One of the few companies to receive the Sword of Honour from the

British safety council.

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One of Indias best technical teams, capable of setting up varied

power plants and of acting as operation and maintenance contractors. Planning projects totaling over 3000MW of new capacity.

SIMPLE CYCLE

The gas turbine operating itself is called as simple cycle. The simple cycle is a constant flow cycle with a constant addition of heat energy .It is commonly referred to as the Brayton cycle, after George Brayton .This cycle is plotted on temperature entropy coordinates .The constant pressure line diverge with increasing temperature and entropy. This divergent of constant pressure line makes the simple cycle gas turbine possible. The term Brayton cycle has more recently been given to the gas turbine engine .This also has three components: A gas compressor A burner(combustion chamber) An expansion turbine Air is compressed from state 1(atmospheric pressure) to state2 in an axial flow compressor, while heat is added between states 2 and 3 in a combustor .Work is then derived from expansion of hot combustion gases from states 3 and 4.Since the expansion from states 3

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to 4 yield more work than that required to compress the air from state 1to 2, useful work is produced to drive a load such as generator. The efficiency of simple cycle is 32%.

COMBINED CYCLE:

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The electricity generated in combined cycle by using both gas turbine generator and steam turbine generator. Gas turbine works on Brayton Cycle and Heat Recovery Steam Generator (HRSG) works on Rankine cycle. A simple Rankine cycle is consist of 4 components the boiler (steam generators ),a turbine, a condenser and a boiler feed pump .The simple cycle is shown on T-S diagram .Note that this boiler has a super heater thus the steam temperature at the entrance of the turbine is above the saturation temperature. The first process in Rankine cycle 3-4 is the increase in pressure of the condensate from the condenser using boiler feed pump. The second Rankine cycle process represented by line 4-1 is addition of heat to water entering the boiler, the conversion of water from liquid to steam and superheating of steam .This process is assumed to occur at constant pressure. The steam is then expanded and cool as it passes through the the turbine as represented by line 1-2.The last process in Rankine cycle is condensation of steam that exhausts from the turbine, represented by line 2-3. The heat required to make the Rankine cycle work is determined by the area under the curve 4-1 and the heat lost from cycle

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is under the curve 3-2.The area between the curve represents the heat which is converted into useful mechanical work. The efficiency of this cycle is about 50%.

ESSAR COMBINED
Fuel Name of the Company

To other CYCLE POWER Boilers PLANT Boiler Exhaust

Deareator

: Essar power ltd

From Other Boilers

Boiler Feed Pump(s)

Type Air cycle

of

the power Combustion

System

Plant plant
Steam Turbine Alternator

: Combined

Compressor

Gas Turbine

Alternator

Condenser Cooling Water Condensate Extraction Pump(s)

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Capacity Configuration of the Plant

: 515MW : 3 Gas turbine generator of 110MW=330MW 1 Steam Turbine Generator of 185MW : NGL/Naphtha/Natural Gas /HSD : Hazira, 27 Km from Surat, 7Km from Surat airport : GT#1 GT#2 GT#3 STG : 14.08.1985 : 15.08.1985 : 13.11.1997 : 26.04.1997

Types of Fuels used Location of the Plant Date of Commissioning

Water Source surat)

Wariv pump house at Tapi river (15Km from

GAS TURBINE

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Vocational Training Report for Combined

MS-9000 gas turbine includes the compressor, combustion chamber, turbine, the turbine casing exhaust frame, exhaust diffusers etc. Model Shaft Speed Maximum firing Temperature Exhaust temperature : Flow : : 1123.8deg C 550deg C 412.9Kg/s : : : PG9171E 1 3000rpm

Technology features:
High reliability High efficiency - Simple cycle 32% and Combined cycle 50% Multi-fuel capability Modular design Low-installed cost High application flexibility On-site maintenance capability Built to operate in remote & hostile environments Emergency start features

The major constructional features are:

17 stage axial compressor Variable inlet guide vanes for optimum efficiency Pressure lubricated 3-bearing system

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Combustion system consisting of 14 nos. reverse flow chambers 3-stage turbine , air cooled first and second stage nozzles an buckets Factory packaged and tested accessory base for easy installation Starting through motor

ACCESSORY COMPARTMENT:
Most of the mechanical and electrical auxiliary equipment necessary for starting and operating the gas turbine is contained within the accessory compartment. There are many systems involved in operation of turbine. Several of these systems have accessory devices, mechanisms, located in the accessory section. These may include the starting, fuel, lubrication, hydraulic, cooling water and atomizing air system. Several major components of the accessories compartment include the starting means, the torque converter and the accessory drive gear.

ACCESSORY EQUIPMENT
BASE MOUNTED AUXILIARIES All turbine auxiliaries are base
mounted to save installation costs and facilitate factory reliability tests of the complete system

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AUXILIARIES OIL PUMPS A variety of oil pumps and drives and

available to meet individual requirements.

STARTING DEVICE Before the gas turbine can be fired and brought
to operating speed it must be first be rotated or cranked by the accessory equipment. This is accomplished by an AC induction motor.

GAUGE PANELS

Instrument grouped in centralized location for

operator convenience.

TORQUE CONVERTER-The starting motor drives the torque

converter through a flexible coupling. It provides the cranking torque and speed required by the turbine or starter. It is coupled to the accessories gear. This same equipment continuous to rotate the turbine rotor at slow speed for cool down purpose. Provides torque multiplication for starting function.

ACC.GEAR BOX The accessory drive gear is the gearing assembly

coupled directly through a flexible coupling to the turbine rotor. Its main function is to drive each gas turbine accessory at its proper speed and to connect the turbine to its starting device. Provides auxiliary drives for main lube oil pump, main atomizing air compressor, main hydraulic supply pump, the liquid fuel pump and the water pump.

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Driven Accessory:
Torque Converter Atomizing Air Compressor Hydraulic Supply Pump Lube Oil Pump : 3000rpm : 6600rpm : 1425rpm : 1425rpm

OIL COOLERS AND FILTERS All lubricant pumped from lube oil
reservoir to the bearing header flows through Dual lube fluid heat exchanger to remove excess heat. Two (Dual) filters are used with a transfer valve installed between the filters to direct oil flow through either filter and into the lube oil header. Only one filter will be in service at a time.

FUEL FLOW DIVIDER The flow divider equally distributes input fuel
flow to the 14 combustion nozzles. It consists of 14 gear pump element in a circular arrangement having a common inlet with a single timing gear. As the fuel enters the flow divider each pair of gear elements distributes one-fourteenth of the fuel flow into each of the fuel lines going to the fuel nozzle.

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COMPRESSOR
The axial flow compressor consists of compressor rotor and the enclosing casing. and the exit guide vanes. In the compressor, air is compressed in stages by a series of alternate rotating (rotor) and stationary (stator) airfoil shaped blades. The rotor blades supply the force needed to compress the air and the stator blades guides the air. Compressed air exit through compressor exit casing. Air is extracted from the diff. stages of compressor is used for sealing and pulsation control. The compressor casing includes the inlet guide vanes, the 17 stages of rotor and stator blading

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o o o o o

Manufacturer Type Compressor Operating Speed Inlet Guide Vane

: General Electric Company : Multi-Stage, Axial Flow

: 11:1 : 3000rpm : Variable-Modulating Type

The main components of compressor are explained below:

ROTOR:
The compressor rotor is an assembly of 17 individual wheels, two stub shafts and compressor rotor blades. Each wheel and the wheel portion of each stub shaft have slots broached around its periphery, the rotor blades are inserted into theses slots.

STATOR:
The stator casing composed of four sections

Inlet casing Forward compressor casing After compressor casing Compressor discharge casing

INLET CASING:
The inlet casing is located at the forward end of the gas turbine. Its prime function is to uniformly direct air into compressor .It also supports the no. 1 bearing housing.

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FORWARD CASING:
The forward compressor casing contains the first 4compressor stator stages. It also transfers the structural loads from the adjoining casing to the forward support.

AFTER CASING:
The after compressor casing contains the fifth through tenth compressor stages. Extraction ports in the casing permit removal of fifth and eleventh stage compressor air. This air is used for cooling and sealing function and also used for pulsation control.

DISCHARGE CASING:
The compressor discharge casing is the final portion of the compressor section. The function of the compressor discharge casing is to contain the final seven compressor stages to form both the inner and outer valves of the compressor diffuser, and to join the compressor and turbine stators.

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COMBUSTION SYSTEM
The combustion system is of the reverse flow type with 14th combustion chamber arranged around the periphery of the compressor discharge casing. This system also includes fuel nozzles, spark plug ignition system, flame detectors and crossfire tubes. High pressure air from compressor discharge is directed into the combustion chamber liner, around the transient pieces.

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This air enters the combustion zone for proper fuel combustion through metering holes and to cool the combustion liner through slots. Fuel supply is through nozzle. Combustion chambers are numbered counter clockwise when viewed looking downstream and starting from the top of the machine.

COMBUSTION WRAPPER:
The combustion wrapper is a fabricated casing that encloses the combustion area and provides a support surface for the combustion chamber assembly. The plenum is formed in which the compressor discharge air flow is directed to the combustion Chamber.

COMBUSTION CHAMBER:
Discharge air from the compressor flows upstream along the outside of the combustion liner towards the liner cap. This air enters the combustion chamber through the fuel nozzle, swirl tip, metering holes in both cap and liner and combustion holes in the forward half of the liner. Additional air is mixed with the combustion in a dilution zone through metering house. Along the length of the combustion liner and liner cap are openings to provide a film of air for cooling the walls of liner and cap.

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NOZZLES:
Each combustion chamber consists of a fuel nozzle. Gaseous fuel is admitted directly into each chamber through metering holes located in the outer valve of the gas swirl tip. The liquid fuel is atomized with air and then spread in the combustion zone. The action of the swirl tips imparts a swirl to the combustion air for proper combustion.

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CROSSFIRE TUBES:
All combustion chambers are interconnected with the help of crossfire tubes. These tubes propagate flame from the fired chambers to the unfired chambers.

SPARK PLUG:
Two high voltage retractable electrodes spark plug are installed in adjacent combustion chamber for initiating the combustion.

FLAME DETECTORS:
During the starting sequence it is essential that an indication of the presence or absence of flame be transmitted to the control system. For this reason, flame monitoring system is used consisting of two sensors which are installed on two adjacent combustion chambers.

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TURBINE SECTION
In the three stage turbine section the energy in the form of high temperature pressurized gas, produced by the compressor and combustion sections, is converted into mechanical energy.

TURBINE ROTOR:
This assembly is consists of two wheel shafts; the first, second and third stage turbine wheels with buckets; and two turbine spacer. The journal for the no.2 bearing is a part of the forward wheel shaft similarly after wheel shaft includes the no.3 bearing journal. The turbine rotor assembly is arranged so that the buckets can be replaced without unstacking the wheels, spacers and wheel shaft assemblies.

BUCKETS:
The turbine buckets increases in size from the first to the third stage. Because of the pressure reduction from energy conversion in each stages, and increased annulus area is required to accommodate the gas flow; thus necessitating increasing the size of the buckets.

STATOR:
The MS-9000 gas turbine stator structure internally supports the turbine nozzles, shrouds, no.3 bearing and turbine exhaust diffuser.

NOZZLE:

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There are three stages of stationary nozzles which direct the high velocity flow of the expanded hot combustion gas against the turbine bucket causing the turbine rotor to rotate. Because of the high pressure drop across these nozzles, there are seals at both the inside and the outside diameter to prevent loss of system energy by leakage. There are mainly three stages of nozzles; first stage nozzles, second stage nozzles and third stage nozzles. Since theses nozzles operate in the hot combustion gas flow they are subjected to thermal stress hence needed to be cooled.

SHROUDS:
The turbine bucket tips run against annular curved segments called turbine shrouds. It provides a cylindrical surface for minimizing bucket tip clearance leakage. It acts as a high thermal resistance between the hot gases and the comparatively cool shell.

EXHAUST FRAME ASSEMBLY:

Exhaust frame assembly consist of the exhaust frame and exhaust diffuser. The exhaust frame is bolted to the after flange of the turbine shell. The exhaust diffuser, located at the extreme after end of the gas turbine, bolts to, and is supported by, the exhaust frame.

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GAS TURBINE AUXILIARY SYSTEMS

FILTERS:
Filters are the primary component of gas turbine. The purpose of filter is to filter out the dust particle at the size of 2 micron. These particles if allowed in may cause severe erosion of compressor and turbine blades. There are three banks of filters and there are in all 1280 filters. The types of filter used are cartridge cylindrical filter. SEA fine dust holding capacity is 5525gm.

PULSATION:
These filters are self cleaning filters. These filters are self cleaned by reverse pulse of high pressure air through filters. This reverse cleaning process is called as pulsation. The pulse frequency is one pulse per minute. At a time 4 filters get the pulsation. The air used for pulsation is bled off from the 11th stage of compressor.

MEEFOG SYSTEM:
The efficient temperature is 15deg.C. But specially in summer it goes beyond 15deg C and ultimately the efficiency drops. To low down the temperature of atmospheric air water at pressure 7Kg/cm2 is sprinkled on the filtered air. This system is called as the MEEFOG system.

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INLET DUCT SCREEN:

Inlet screens are provided immediately upstream of the initial filters to prevent the entry of leaves, twigs papers and other similar objects. These screens must be kept free from any excess accumulation of such debris to ensure free air flow.

TURBINE STARTING SYSTEM:

The starting motor is used for rotating or cranking turbine before it can be fired and started. Typically, the Gas turbine becomes self sustaining at 60 % speed after which the starting motor is withdrawn. The starting system consists of an induction motor and torque converter coupled to accessory gear. A motor driven torque

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adjustor drive forms an integral part of the torque converter system which provides means for adjusting torque output within specified ranges.

TURBINE /GEN. LUBRICATING OIL SYSTEM:

The lubricating oil is used for main turbine bearings, generator bearings, accessory gears and the Lube oil circuit also feeds the Hydraulic oil & Trip oil circuits. It is also used as hydraulic fluid in starting means torque converter. System components: 1. Main lube oil pump (Shaft driven from acc. gear) 2. Auxiliary lube oil pump (AC motor driven submerged centrifugal pump) 3. Emergency lube oil pump (DC motor driven sub merged centrifugal pump) 4. Lube oil reservoir in Accessory Base approx. 10 KL capacity. The Aux. lube oil pump provides oil during gas turbine startup and when main pump cannot supply adequate pressure for safe operation.. The Aux. Oil pump cuts off capable of delivering oil for at the Gas turbine speed of 95%. During full speed operation the shaft driven main oil pump is all the above functions . Emergency

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lube oil pump supplies lube oil during emergency conditions e.g. Loss of AC power & avoids damage to the bearings.

TURBINE TRIP OIL & HYDRAULIC SYSTEM:

The gas turbine protection system is designed to provide for a safe shutdown of gas turbine . The protections are strictly for abnormal and emergency operating condition requiring immediate shutdown of the Turbine. The Hydraulic oil is the high pressure oil required to operate the fuel valves & the IGVs as per the command from the Speedtronic mark V. The Trip oil is the primary interface between the turbine control and protection system circuits (SPEEDTRONIC control system) and the Fuel valves on the turbine which admit or shut off fuel. In the event of a trip initiation , the trip oil drains out causing the Hydraulic oil circuit to be depressurized . This results in the fuel valves to close.

ATOMISING AIR SYSTEM:

Liquid fuels require to be broken into particles by highpressure atomizing air, which increases surface area, and hence complete and proper combustion is achieved. Air for this purpose is taken from last stage of the compressor, and the pressure is increased before delivery to the nozzle.

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System components: 1. Main atomizing air compressor. 2. Booster air compressor. 3. Atomizing air heat exchanger. During turbine start up, atomizing air is supplied by motor driven booster compressor, because accessory gear driven main compressor does not deliver sufficient pressure at low turbine speed. Booster compressor shutdown at 95% turbine speed during startups. For maintaining a uniform inlet temperature to the atomizing air compressor, air taken from the atomizing air extraction is passed through air-to-water heat exchanger.

COOLING AND SEALING AIR SYSTEM:

The air drawn from the compressor fifth stage is used for feeding air to the cooing and sealing air system . This system provides necessary air flow to the parts of the rotor and stator for 1. Cooling of Internal turbine parts subjected to high temperature like shrouds in the stator. 2. Sealing of Turbine exhaust side & Compressor inlet side bearings.

TURBINE VENTILATING SYSTEM:

Ventilating system is provided in turbine, accessory and load compartment for ventilating hot air & for removing the fuel oil

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fumes from the turbine / accessory compartment which can be a safety hazard. The vent fans, driven by an AC motor pulls air into accessory compartment and after circulating, exhaust the heated air out through vertical stack. In turbine compartment-cooling air is brought in through six ventilating louvers and heated air is exhausted through vent fans located on turbine compartment roof. Cooling air for load compartment is brought in through two ventilation openings and heated air is exhausted through vent fan.

COMPRESSOR WATER WASH SYSTEM:

Gas turbines can experience a loss of performance during operation as a result of deposits of atmospheric components such as dirt, insects, dust and hydrocarbon film on compressor parts which occur with the ingestion of air. Most of these can be removed by inlet air filtration however, the dry components that pass through the filters as well as wet contaminants ,have to be removed periodically by washing with a water and detergent solution followed by a water rinse. Water wash may be performed both on - line as well as off - line.

GAS

FUEL SYSTEM:
Gas fuel system is designed to deliver gas fuel to

turbine combustion chamber at the proper pressure and flow rates to meet all of the starting, accelerating and loading of gas turbine. Gas

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comes through the scrubbers where it loses the condensates and passes through the filters where the dust is removed. The filtered gas is delivered to the gas turbine where a stop ratio valve maintains the pressure of the gas at desired value . The gas quantity fed into the gas turbine is controlled by a control valve which is controlled by Speedtronic Mk V . Gas is supplied to each combustion chamber from a ring which equally divides the gas in to 14 parts and is supplied to the can through individual lines.

LIQUID FUEL SYSTEM:

OFF-BASE fuel system consists of fuel tanks, forwarding pumps and fuel selection skid. The pumps provide the fuel at required pressure to the fuel selection skid where it gets filtered through Off-base filters and after metering it goes to On-base filters in accessory compartment. ON-base liquid fuel system consists of hydraulically operated stop valve, filters, gear driven screw pump, and flow divider. Fuel after filtration , is supplied equally to 14 nozzles of combustion chambers by flow divider at required pressure and flow rate, provided by shaft driven screw pump . In the event of turbine tripping hydraulic oil gets drained and stop valve closes. Since NGL and NAPTHA have very low lubricating property lube oil is added to through

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lubricity injection module where Hitec is added to the fuel with the help of pumps at the required rate. Lubricator pump provides forced lubrication to the bearings of the main fuel oil pump .

LIQUID FUEL SYSTEM (HSD):

HSD is used as the start up liquid fuel. After the Gas Turbine starts generating power, the fuel is changed over to Naphtha. To remove entrapped naphtha from combustion system during gas turbine startup and shut down & also in the event of a trip, HSD is used as the draining medium and procedure is called as Naphtha draining. After draining has been accomplished fuel is pumped back to the storage tank by an AC driven pump. This system is known as waste fuel drainage system.

GAS TURBINE AUXILIARY COOLING WATER SYSTEM:

The cooling water system is a closed system designed for cooling the Turbine and generator lube oil, the atomizing air and Turbine supports. It consists of both on -base and Off-base mounted components. The On-base components include 1. Lube fluid heat exchangers in Accessory base. 2. Turbine support legs. 3. Four Nos. Heat exchangers of generator hydrogen cooling system. 4. Flow regulation valves orifices.

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The off base system comprises cooling towers pumps.

& ACW circulation

TURBINE SUPPORTS:
The gas turbine is mounted to its base by vertical supports at three locations; the forward supports at the lower half vertical flange of the forward compressor casing and the after two on either side of the turbine exhaust frame. The outer surface of each after support leg is a water jacket. Cooling water is circulating through the jackets is to minimize thermal expansion of the support legs and assist in maintaining alignment between the turbine and the generator. The support legs maintain the axial and vertical position of the turbine, while a gib key coupled with the turbine support legs maintains its lateral position.

BEARINGS:
The MS-9000 GT unit contains three main journal bearing used to support the gas turbine rotor. No 1bearing: It is located in the center of the inlet casing assembly and contains three bearings active thrust bearing, inactive thrust bearing and journal bearing. No. 2 bearing: It is located in the center of the inner cylinder of the compressor discharge casing.

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No. 3 bearing: It is located at the after end of the turbine shaft in the

center of the exhaust frame assembly.

HEAT RECOVERY STEAM GENERATION

INTRODUCTION:
In the simple cycle the temperature of the exhausted gas leaving a gas turbine can be high as 1100degF.High temperature gas represents a source of heat energy .Some of which are recovered if there is any alternative to do so .By recovering the waste heat the output and efficiency of power plant can be increased . The function of HRSG is to recovery the waste heat available in exhaust gases and transfers it to the water and steam. The heat recovered is used to generate steam at high pressure and temperature .Additional power in a steam turbine driven generator is generated from the steam .HRSG provides the critical link between the gas turbine and Rankine cycle in the combined cycle plant.

OPERATION:
The condensate from gland steam condenser passes through condenser preheated (CPH) and then to deaerator. In deaerator the excess gases are removed .In feed water tank (FWT) the steam is taken from LP mean steam header which is called as pegging .To

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increase the temperature to the saturation temperature(118degC) at a pressure of 1.2bar which increases the rate of oxygen release. Then this DM water in pump through three individual LP and HP feed water system.

HIGH PRESSURE WATER / STEAM FLOW PATH

After passing through the feed water regulating valve the water flows through high pressure low temperature(HPLT)economizer ,then the water flows through the high pressure intermediate temperature( HPIT ) economizer and passes through high pressure high temperature(HPHT) economizer. After leaving HPHT economizer, the water enters HP steam drum through feed water inlet nozzle and continuous to the HP evaporator .Natural circulation is maintained in the HP evaporator by means of two down comers which feed the water to the lower evaporator headers. The steam is generated and flows upward in the evaporator tubes .The saturated water steam mixture is conducted from the upper HP evaporator to the HP drum through 24 risers .The saturated steam separated from the saturated water steam mixture by the drum internals and then exit through two saturated steam outlets. The saturated steam leaving the drum passes through the HPLT S/H .The

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steam then flows through HPIP S/H, then through the desuperheater where small portion of water is tapped from the FWT and used as spray water for HP S/H desuperheater to minimize the temperature and then pass through HPHT S/H .The steam leaving the HPHT S/H is combined into the HP outlet steam header. As there are three gas turbines connected to three HRSG, three HPHT S/H outlets are connected to main HP steam header

LOW PRESSURE WATER /STEAM FLOW PATH

The water from FWT is pumped through three LP FWP and passes through the feed regulating value. The LP feed water enters the HRSG at the LP economizer. The water flow through LP economizer enter the LP steam drum through the feed water inlet nozzle and continuous on the LP evaporator. Natural circulation is maintained by means of two down comers. Steam is generated and flows upward in the evaporator tubes. The saturated water steam mixture is conducted to the LP steam drum through 14 risers. The saturated steam separated and exit through two saturated steam output. The saturated steam outlet direct the LP saturated steam to the single stage LP S/H and combines with the LP steam outlet header. As there are three HRSG, three LP S/H outlets are connected to the LP common header.

GAS SIDE FLOW PATH

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The exhaust passes through the diverter damper and then will pass by the pressure section in the following order. HPHT S/H --- HPIT S/H --- HPLT S/H --- HP EVAPORATOR---HPHT ECONOMISER --- HPIT ECONOMISER --- LP S/H --LP EVAPORATOR --HPLT ECONOMISER --LP ECONOMISER --- CONDENSATE HEATER . The exhaust gas will leave condensate heater and exit the HRSG through the main exhaust stack.

HP AND LP BYPASS SYSTEM

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The HP and LP steam bypass is a primary safety device for HRSG against over pressurization. In the event of steam turbine trip , the entire steam production of HRSG is diverted through the condenser by means of HP and LP bypass valve. The steam dumped to the condenser is mixed with the desuper rating water spray to avoid high temperature in condenser. The bypass steam also allows steam generator to gradually buildup the pressure and temperature of HP and LP during start up. This system enables hot restarting of unit and warming up steam line.

DRUM
The main function of drum is to reduce the moisture content of saturated steam leaving the drum by mechanical means. The feed water is fed to the drum through the feed water nozzle. The water then enters the down comers and the steam water mixture enters through risers. The steam water mixture is collected in the internal compartment the saturated steam travels through turbo separators which is also called as centrifugal separators as it works on the principle of centrifugal action. When the steam water mixture enters the turbo separators due to the spinning action, the centrifugal force act on the steam water mixture. The saturated steam at high velocities there by loses most of its entrained water and enters the corrugated plate driers. The drier directs the steam and forces any remaining entrained

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water against the corrugated plates since the velocity is relatively low, this water can not be picked up again and runs down the corrugated plates and returns to the lower part of drum. HP operating pressure HP operating temperature LP operating pressure LP operating temperature : 84.5Kg/cm2 : 298.3degC : 6Kg/cm2 : 164.4degC

COTINUOUS BLOW DOWN LINE (CBD):

CBD line controls the concentration of the soluble solids in the boiler water because it constantly removes a small portion of solids and their by maintains relatively constant concentration in the boiler water.

INTERMITTENT BLOW OFF LINE (IBD):

IBD should always be used to free a boiler of sediment , when the boiler is being shut down .The should be blow down at least once every 24 hour or more often during commissioning if the water is of inferior quality or the amount of make is large .

SAFETY VALVE:

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It serves to protect pressure vessels from overpressure on S/H outlet .They serve the additional purpose of protecting the S/H from over heating in the event of sudden interruption in the steam consumption.

WATER LEVEL INDICATOR:

The main function of the water level indicator is to indicate the water level inside the drum, which should be at normal set value.

CHEMICAL DOSING:
Trisodium phosphate is used for maintaining the pH of the water inside the drum .The pH is maintained at 9.5.

Vocational Training Report for Combined

Vocational Training Report for Combined

STEAM TURBINE AND GENERATOR Steam turbine coverts heat energy of steam to mechanical energy .Steam turbine consists of two section High pressure and Low pressure. HP steam is supplied from common main steam header from all three HRSG the LP steam is supplied from the common LP main steam header through one stop and control valve. LP steam enters after last stage of HP turbine where it mixes with HP steam which has already done its work. Then finally it enters the LP turbine through crossover pipe. Type Rating Speed HP steam flow LP steam f low HP Throttle Temperature HP Throttle Pressure LP Throttle Temperature LP Throttle Pressure : : : : : : : : : Impulse Turbine 186.1MW 3000rpm 526.56T/hr 606.3T/hr 520deg C 76Kg/cm2 205degC 5.1Kg/cm2

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HP turbine stages LP turbine stages :

11 16

Generator uses hydrogen as cooling medium .There are 4 Nos. of water cooled heat exchanger for cooling hydrogen. The hot water is then cooled in Induced draught cooling tower (IDCT) for further recirculation.

Generator parameter Type Voltage Ampere Output : Hydrogen cooled : 240540 KVA : 9258 A : 15 KV

CONDENSER SYSTEM
The condenser helps in converting the exhaust system into water thus allow recycling of DM water .The condensate system consist of condensate system and extraction system. Condensation of LP exhaust steam from by pass system and all the drain are connected to the condenser. Condenser is of surface type and condensation of steam takes place at the surface of the tubes

Vocational Training Report for Combined

which are cooled by cooling water flowing inside them. This cooling water gets heated up due to the heat transfer. This hot water is then sent to the IDCT for cooling process with the help of 18 induced draught fans.

STEAM TURBINE AUXILIARY SYSTEMS

GENERATOR COOLING SYSTEM:
The generator is cooled by hydrogen due its higher heat transfer coefficient the hydrogen is then cooled by the cooling water system. A 30 psi of Hydrogen pressure is maintained within the generator and the gas is circulated within the generator housing with the help of fans fixed on the rotor .The gas absorbs heat from the generator windings . To maintain the purity of hydrogen continuous scavenging is done. Hydrogen is sealed in the turbine with the help of the seal oil which is derived from lube oil at little higher pressure than the H2 pressure. In the event of loss of seal oil pressure or very low purity of the hydrogen automatic emergency purging of hydrogen takes place. The Hydrogen, in such cases is purged with the help of CO2 which is supplied from the CO2 skid.

COOLING WATER SYSTEM:

To cool the lube oil, Generator and the Auxiliaries, cooling water system is provided which consists of 4 x 33% AC motor driven pumps and 4 X 33 % IDCT fans .Duplex filters are provided to filter

Vocational Training Report for Combined

dirt out

of

the

cooling

water .

The cooling water chemistry is

maintained by means of chemical treatment.

FIRE PROTECTION:
Fire protection is provided for Load & Turbine & compressor Compartment. In the event of detection of fire, solenoid tank gets operated. The CO2 fire protection system extinguishes fire by reducing the O2 content of the air in the compartment from an atmospheric normal of 21% to less than 15 %, an insufficient concentration to support combustion. To reduce O2 content, a quantity of Co2 equal to or greater than 34% of compartment volume is discharged into the compartment in one minute, and recognizing the reflash potential of combustibles exposed to high temperature metal it provides an extended discharge to maintain an extinguishing concentration for a prolonged period minimize the likelihood of a reflash condition. to valve of CO2

Vocational Training Report for Combined

Vocational Training Report for Combined

WATER TREATMENT PLANT

FUNTIONS:
To minimize the amount of corrosion products such as oxides of iron, copper and nickel .These oxides invariably plate out on heat transfer surface which must be periodically remove.

To minimize the hardness causing impurities such as magnesium,

Calcium, silicon .This impurity causes hard adherent scale formation which results in tube failure. To remove organic impurities, suspended solids, floating impurities from raw water.

WATER TREATMENT PROCEDURE:

Raw water:
Raw water source for ESSAR PLANT is from warior pump house situated on Tapi river located 15 Km from Hazira. If there is any discontinuity in raw water inlet from warior, then there is another substitute where in the raw water intakes from water sump located at ESSAR Steel plant. The raw water is stored in the raw water sump. The water level in the sump is indicated with the help of 10 steps which are counted from top. If the water level reaches 1.5 the intake of water stops

Vocational Training Report for Combined

and if the level reaches the step 6 the water intake is started. By any reason the water level reaches the 9th step then there is difficulty in suction hence the plant trips.

CLARIFLOCULATER:
Dosing:
Alum is added as a coagulant, which helps in coagulating the suspended particle from the raw water. Amount of alum added =2.5Kg\hr Chlorine act as anti bacterial chemical .Polyelectrolyte is added as a catalyst which increases the rate of reaction.. The water is brought up in the mixing chamber, where it mixes properly for the increase in the rate of reaction. Then the water from mixing chamber is divided into two Clarifloculator which consist of two circular concentric tanks. In central tank there is a moving body which moves at the rate of 30min\rev. In the clarifloculator, the raw water undergoes sedimentation, coagulation, flocculation, chlorination.Then it is accumulated in water storage tank Type of clariflocculator : Capacity : vertical centrifugal 1200m3\hr

Vocational Training Report for Combined

SOFTEN WATER PLANT:

The water from clarified water storage tank is pump with the help of clarified water pump to the soften plant .In soften plant the water is sampled and accordingly the sodium sulphite is added which is then pass through pressurized sand filter (PSF).PSF is the tank containing layer of sand and is also pressurized. The water from PSF is divided into two, 95% is sending to soften tank which is completely filled with resin and 5% is stored in the filter water tank. The 95% water coming out from soften plant is sent to induced cooling tower (IDCT) fore bay and gas turbine cooling tower (GTCT). R-Na +CaCO3 R-Ca +NaCO3 R-Na +MgSO4- R-Mg+NaSO4

Vocational Training Report for Combined

WATER TREATMENT PLANT

Vocational Training Report for Combined

DEMINERALISING PLANT The 5% water from PSF which is stored in filter water tank is allowed to pass through the activated carbon filter (ACF) and then it is used for two purposes. -Drinking -DM water

NEED OF DM PLANT:
The DM water is used in STG, GTG and in condenser for cooling and make up purpose .this water should be mineral free or else these mineral react with metal pipe lines and cause the damage. gas The DM water is also used in generator usually to cool the hydrogen used for cooling purpose.

DM PLANT PROCESS
The water from ACF is treated in DM plant as follows:

1. SAC (Strong Acid Cation):

When water is pass through SAC the cations are removed from the water as follows: R-H++ CaCO3 R-H+ + CaCl R-Ca + HCO3 R-Ca + HCL

Vocational Training Report for Combined

R-H+ + MgSO4 R-H+ + NaCL R-H+ + CaSO4

R-Mg + H2SO4 R-Na + HCL R-Ca + H2SO4

2. DEGASSER:
In degasser the water is allowed to fall from particular height and the gas is blown just below that of water fall by a degasser pump as a result all the gases especially CO2 removed from the water. HCO3-+ O2 CO2 + H2O
3.

SBA(Strong Based Anion):

When the gas is passed through all the anion are removed as followsR-OH-+ HCL R-CL + H2O

R-OH- + H2SO4 R-SO4 + H2O

Vocational Training Report for Combined

4. MIXED BED:
When the cations and anions which are not being removed in SAC and SBA are removed by passing through mixed bed

which contain SAC as well as SBA resin.

REGENERATION:
After some time, the ability of SAC and SBA resin to exchange cations and anions gets exhausted and so regeneration is a necessary process.

Vocational Training Report for Combined

The regenerate HCl is used in case of SAC and caustic soda is used in case of SBA .In MB both HCl and caustic soda is used. The reactions are given below.

SCA:
R-Ca + HCl R-H + CaCl R-Mg + HCL R-H + MgCl R-Na + HCl R-H + NaCl

SBA:
R-Cl + NaOH R-OH + NaCl

R-SO4 + NaOH R-OH + NaSO4

Vocational Training Report for Combined

Vocational Training Report for Combined

I had an extremely memorable experience here with personas like Mr. Jay Patel (EPoL.), Mr. Gaurav Punj (EPoL.), Mr. Vivek Makode (BPoL.), Mr. Mithul Patel (BPoL.) and last but surely not the least Mr. Ramesh Reddy (HOD, mechanical department). I am also very grateful to the Essar family for lending out such supporting hands to the young engineers like us. The working conditions here are such that it will take the best out of you, no matter what. I am sincerely in debt to the other heads of various departments for being so cooperative and understanding and also the back bone of this organization- the technicians; they were of great support and took a great interest in us. I pay all of you sincere thanks.