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INTERNSHIP REPORT
CERTIFICATE
This is to certify that Akshay Malik , student of B-Tech Branch
Mechanical, Batch 2012-2016 of Delhi Technological University successfully
completed his industrial training at Pragati Power Corporation Limited (PPCL)
Power Plant Pragati-1,New Delhi for four weeks from 9th June to 4th July. He
has completed the whole training as per the training report submitted by him.
ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training at
PRAGATI POWER CORPORATION LIMITED.
I extend my thanks to Mr. V.P. SINGH for providing me this opportunity to be a part of this esteemed
organization.
I would also like to offer my sincere thanks to the technical staff of PPCL for their co-operation and guidance
that helped me a lot during the course of my training. I have learnt a lot working under them and I will always be
indebted of them for this value addition in me.
INTRODUCTION
Pragati Power Corporation Ltd. (PPCL)
The Company
Pragati Power Corporation Limited is an undertaking of Government of NCT of Delhi. It was incorporated
on 9th January,2001 to undertake power generation activities for supplying power to Delhi. It is one of
the leading Undertakings of GNCTD, generating profits since inception and paying dividends regularly. It
is presently having capital base of 2,019 crores and asset base of 3,319 crores. The projected asset
base and revenue income of Company in the near future are 6,000 crores and 5,000 crores
respectively. The first project undertaken by the company was 330 MW gas based CCGT which was fully
commissioned in the year 2003-04. The station is presently operating at above 85% availability.PPCL is
presently setting up a 1500 MW Gas Based CCGT plant at Bawana in North-West Delhi to augment the
power generation at Load-Centre. Project is expected to fully commission by July 2011. PPCL is also
proposing to put up a 750 MW Gas Based CCGT at Bamnauli in South-West Delhi. The project is expected
to be commissioned in the year 2013-14.
To have reliable supply to the Capital City, a 330 MW combined cycle Gas Turbine Power Project was set
up by PPCL on fast track basis. The plant consists of 2 x 104 MW GE Frame 9-E Gas Turbine Units
commissioned in 2002 03 and 1 x 122 MW STG Unit commissioned in 2003 04. The station is using
APM, PMT and R-LNG Gas, supplied by GAIL through HBJ Pipeline. The station is performing well and has
achieved
availability
of
more
than
85%.
The power generation from the station is pumped to the adjacent 220kV Sub Station of Delhi Transco
Limited and the entire power is supplied to the discoms of Delhi i.e. NDPL, NDMC, BRPL & BYPL. The
Special features of the plant are as under:
Due to paucity of water in the capital city, the plant is operating on treated sewage water supplied
from Sen Nursing Home & Delhi Gate STPs. The STP water is further treated in RO-DM Plant.
Emission of oxides of Nitrogen (Nox) has been limited to 35 PPM, lowest in the country, for which
special technology is used by installing Dry Low Nox (DLN) Combustors. This is the first plant in India
with a facility to control Nox. Emission.
The plant effluent is discharged to river Yamuna after neutralizing and thus the effluent discharge is
better than river water, making the project eco-friendly.
Gas Turbine:
A gas turbine, also called a combustion turbine, is a rotary engine that extracts energy from
a flow of combustion gas. It has an upstream compressor coupled to a downstream turbine, and a
combustion chamber in-between. (Gas turbine may also refer to just the turbine element.)
Energy is added to the gas stream in the combustor, where air is
m i x e d w i t h f u e l a n d i g n i t e d . C o m b u s t i o n i n c r e a s e s t h e t e m p e r a t u r e , velocity and
volume of the gas flow. This is directed through a nozzle over the turbine's blades, spinning the turbine
and powering the compressor.
Energy is extracted in the form of shaft power, compressed air and
t h r u s t , i n a n y c o m b i n a t i o n , a n d u s e d t o p o w e r a i r c r a f t , t r a i n s , s h i p s , generators, and
even tanks.
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.
The term Brayton cycle has more recently been given to the gas turbine engine. This also has three
components:
1. a gas compressor
2. a burner (or combustion chamber)
3. an expansion turbine
Ideal Brayton cycle:
1. isentropic process - ambient air is drawn into the compressor, where it is pressurized.
2. isobaric process - the compressed air then runs through a combustion chamber, where fuel is
burned, heating that aira constant-pressure process, since the chamber is open to flow in and
out.
3. isentropic process - the heated, pressurized air then gives up its energy, expanding through a
turbine (or series of turbines). Some of the work extracted by the turbine is used to drive the
compressor.
4. isobaric process - heat rejection (in the atmosphere).
Actual Brayton cycle:
1.
2.
3.
4.
The effects of inlet air filtration are both positive and negative. The negative side of filtration is that
whatever is placed in the path of air coming into the gas turbine causes a pressure loss, resulting in
reduced performance or efficiency of the machine. However, inlet filtration will help sustain the gas
turbines performance above an acceptable level and minimize the occurrence of the degradation effects
discussed above. Turbine inlet filtration becomes a trade-off. Cleaner air with reduced particle or
moisture content controls wear and fouling at reduced efficiency. Unfiltered or less-filtered air at lower
pressure loss gives better efficiency initially, but the dirty air can result in temporarily or permanently
damaged machinery internal parts. Thus, it is clear that filtration is needed. The challenge is to keep
pressure loss to a minimum while removing a satisfactory amount of particles and moisture.
Effective filtration can require several filter stages to remove different materials from the air, or to
remove more particles, different phases (solid, liquid), or smaller particles. Filters to remove rain and
snow, mist, smoke or dust, and finer particles all require variations in filter design. The most common
approach to meet these varied needs is the use of multiple stage filtration systems, usually with two or
three stages, each stage with a different purpose and design.
Compressor
Compressor used in gas turbine is Axial Flow type
High Performance Made Possible by Advanced Aerodynamics, Coatings, and Small Blade Tip Clearances
Even Small Amounts of Deposits on Compressor Blades May Cause Large Performance Losses
As air flows into the compressor, energy is transferred from its rotating blades to the air. Pressure and
temperature of the air increase.
Most compressors operate in the range of 75% to 85% efficiency.
Combustion Chamber
The purpose of the combustor is to increase the energy stored in the compressor exhaust by raising its
temperature. Combustion air, with the help of swirler vanes, flows in around the fuel nozzle and mixes
with the fuel. This air is called primary air and represents approximately 25 percent of total air ingested
by the engine. The fuel-air mixture by weight is roughly 15 parts of air to 1 part of fuel. The remaining 75
percent of the air is used to form an air blanket around the burning gases and to lower the temperature.
Turbine Section
The three-stage turbine section is the area in which the energy in the hot pressurized gas produced by
compressor and combustion sections is converted into mechanical energy.
The first stage of turbine rotor blade consists of blades.
Air cooling arrangements are provided for turbine 1st and 2nd stage.
Exhaust System
Simple Cycle Stack
Transition to HRSG
Steam Turbine
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam,
and converts it into useful mechanical work. The available heat energy of the steam first is converted into
kinetic energy by the expansion of the steam in suitably shaped passage, or nozzle, form which it issues
as a jet, at a proper angle, against curved blades mounted on a revolving disk or cylinder and by the
reaction of the jet itself as it leaves the curved passage. The pressure on the blades, causing rotary
motion, is solely due to the change of momentum of the steam jet during its passage through these blades.
The steam energy is converted mechanical work by expansion through the turbine. The
expansion takes place through a series of fixed blades (nozzles) and moving blades each row of fixed
blades and moving blades is called a stage. The moving blades rotate on the central turbine rotor and the
fixed blades are concentrically arranged within the circular turbine casing which is substantially
designed to withstand the steam pressure. On large output turbines the duty too large for one turbine
and a number of turbine casing/rotor units are combined to achieve the duty. These are generally
arranged on a common centre line (tandem mounted) but parallel systems can be used called cross
compound systems.
Working Cycle
The steam turbine works on rankine cycle, the Rankine cycle is a thermodynamic cycle which
converts heat into work. The heat is supplied externally to a closed loop, which usually uses steam as the
working fluid. A Rankine cycle describes a model of the operation of steam heat engines most commonly
found in power generation plants. Common heat sources for power plants using the Rankine cycle are
coal, natural gas, oil, and nuclear.
Process 1-2: The working fluid is pumped from low to high pressure, as the fluid is a liquid at this stage
the pump requires little input energy.
Process 2-3: The high pressure liquid enters a boiler where it is heated at constant pressure by an
external heat source to become a dry saturated vapour.
Process 3-4: The dry saturated vapour expands through a turbine, generating power. This decreases the
temperature and pressure of the vapour, and some condensation may occur.
Process 4-1: The wet vapour then enters a condenser where it is cooled at a constant pressure and
temperature to become a saturated liquid. The pressure and temperature of the condenser is fixed by the
temperature of the cooling coils as the fluid is undergoing a phase-change.
Constructional Features:
The steam turbine at P.P.C.L has a tandem compound shaft arrangement with H.P and L.P section.
1) H.P turbine:
The H.P turbine is of single flow, double shell construction with horizontally split casings
allowance is made for thermal movement of the inner casing within the outer casing. The main steam
enters the inner casing from top and bottom.
2) L.P turbine:
The casing of the double flow L.P turbine is of three shell design. The shells are of horizontally
split welded construction. The inner casing which carries the first rows of stationary blades is supported
on the outer casing so as to allow for thermal expansion.
3) Blading:
The entire turbine is provided with reaction blading. The moving blades of H.P turbine and the
initial rows of L.P turbine with inverted T roots and integral shrouding are machined from solid
rectangular bar.
4) Bearings:
The H.P rotor is supported on two bearings a combined journal and thrust bearing at its front and a
journal bearing close to the coupling with L.P motor. The L.P rotor has a journal bearing at its end. The
combined journal and thrust bearing takes up residual thrust from both directions.
The shaft gland seals the steam inside the cylinders against atmosphere and the interstage seals
restrict leakage at blade tip.
6) Valves:
Steam enters the turbine from the HRSG into a series of valves. These valves are controlled by
the governor with regulates the amount of steam passing through the turbine in order to maintain the
constant speed required to generate power at 50 cycles per second.
Technical specification:
H.P turbine
L.P turbine
:2
:2
Speed:Rated Speed
: 50.0/s
: 47.5/s
Power Station
Station
Station Capacity (MW)
Units (MW)
Year of Commissioning
Gas
Water Sources
Beneficiary Areas
Condenser
The surface condenser is a shell and tube heat exchanger in which cooling water is circulated
through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is cooled
and converted to condensate (water) by flowing over the tubes. Such condensers use steam ejectors
or rotary motor-driven exhausters for continuous removal of air and gases from the steam side
to maintain vacuum For best efficiency, the temperature in the condenser must be kept as low as
practical in order to achieve the lowest possible pressure in the condensing steam. Since the condenser
temperature can almost always be kept significantly below 100C where the vapour
pressureof water is much less than atmospheric pressure, the condenser generally works under vacuum.
Thus leaks of non-condensable air into the closed loop must be prevented. Plants operating
in hot climates may have to reduce output if their source of condenser cooling water
becomes warmer; unfortunately this usually coincides with periods of high electrical
demand for air conditioning. The condenser uses either circulating cooling water from a
cooling tower to reject waste heat to the atmosphere, or once-through water from a river.
Cooling Tower
A cooling tower is a heat rejection device, which extracts waste heat to the atmosphere though the cooling of
a water stream to a lower temperature. The type of heat rejection in a cooling tower is termed "evaporative"
in that it allows a small portion of the water being cooled to evaporate into a moving air stream to provide
significant cooling to the rest of that water stream. The heat from the water stream transferred to the air
stream raises the air's temperature and its relative humidity to 100%, and this air is discharged to the
atmosphere. Evaporative heat rejection devices such as cooling towers are commonly used to provide
significantly lower water temperatures than achievable with "air cooled" or "dry" heat rejection devices, like
the radiator in a car, thereby achieving more cost-effective and energy efficient operation of systems in need
of cooling. Think of the times you've seen something hot be rapidly cooled by putting water on it, which
evaporates, cooling rapidly, such as an overheated car radiator. The cooling potential of a wet surface is much
better than a dry one.
Value
Parameters
Value
pH
6.8 to 8.5
FRC
Nil
COND
1300 to 1800
PHOSPHATE
0.1
ALKALINITY
260 to 400
SILICA
25 to 30
TOTAL
HARDNESS
260 to 340
TURBIDITY
<15 NTU
CALCIUM
140 to 230
COD
<150
CHLORIDE
160 to 230
Organic matter
<150
IRON
0.2
BOD
AERATOR
Raw water form
DG & SNH
RESERVOIR -A
16000m3
RESERVOIR B
16000m3
SUMP
RAW WATER
PUMP - A
675m3
RAW WATER
PUMP B
675 m3
Parameters
Value
Parameter
Value
pH
9.8 to 10.2
CHLORIDE
180 to 250
COND
IRON
0.2
ALKALINITY
1300 to
1800
280 to 400
FRC
TOTAL HARDNESS
160 to 250
PHOSPHATE
0.1
CALCIUM
80 to 150
SILICA
25 to 30
COD
100 to 120
TURBIDITY
<30 NTU
BOD